Honda Marine BF135A Manual Download Page 193

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BF135A•BF150A

5-40

DTC 13-2: BARO sensor voltage is high

1. Symptom reproduction test

-1. Connect the HDS pocket tester and clear the DTC

once. If the DTC can not be cleared, go on the trou-
bleshooting.

-2. Turn the ignition switch ON.
-3. Measure the BARO sensor (PA) voltage using the

HDS pocket tester.

Is the measurement voltage 1.58 – 4.49V?

YES –

Temporary failure (Disappeared)

NO –

Perform “2. BARO sensor power line check”.

2. BARO sensor power line check

-1. Turn the ignition switch OFF and disconnect the BARO

sensor 3P connector.

-2. Turn the ignition switch ON. Measure the voltage

between the No. 3 (Brown/White) and the No. 1
(Green/Red) terminals of the BARO sensor harness
side 3P connector.

Is the measurement voltage 4.75 – 5.25V?

YES –

Perform “4. BARO sensor signal line open cir-
cuit check”.

NO –

Perform “3. BARO sensor power line open cir-
cuit check”.

3. BARO sensor power line open circuit check

-1. Turn the ignition switch ON. Measure the voltage

between the No. 3 (Brown/White) terminal of the
BARO sensor harness side 3P connector and the
engine ground.

Is the measured voltage 4.75 – 5.25V?

YES –

Repair open in the wire between the BARO
sensor and the engine ground.

NO –

Repair open in the wire between the BARO
sensor and the ECM.

4. BARO sensor signal line open circuit check

-1. Turn the ignition switch ON. Measure the voltage

between the No. 2 (White/Blue) terminal of the BARO
sensor harness side 3P connector and the engine
ground.

Is the measured voltage 4.75 – 5.25V?

YES –

Perform “5. BARO sensor check”.

NO –

Repair open in the wire between the BARO
sensor and the ECM.

5. BARO sensor check

-1. Turn the ignition switch OFF and connect the BARO

sensor connector.

-2. Turn the ignition switch ON and measure the BARO

sensor voltage using the HDS pocket tester.

Is the measured voltage 2.76 – 2.96V?

YES –

Substitute a known-good ECM and recheck.

NO –

Replace the BARO sensor and recheck.

BARO SENSOR HARNESS
SIDE 3P CONNECTOR

SG2
(GREEN/RED)

VCC2
(BROWN/WHITE)

VIEWED FROM THE
TERMINAL SIDE

BARO SENSOR HARNESS
SIDE 3P CONNECTOR

VCC2 (BROWN/WHITE)

VIEWED FROM THE
TERMINAL SIDE

BARO SENSOR HARNESS
SIDE 3P CONNECTOR

PA (WHITE/BLUE)

VIEWED FROM THE
TERMINAL SIDE

Summary of Contents for Marine BF135A

Page 1: ...st use your own good judgment You will find important safety information in a variety of forms including Safety Labels on the engine cover Safety messages Preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if you don t follow instr...

Page 2: ...3 CHECK POINT 2 44 10 CABLE HARNESS ROUTING 2 45 11 TUBE ROUTING 2 66 12 LUBRICATION 2 77 3 MAINTENANCE 3 1 1 MAINTENANCE SCHEDULE 3 1 2 ENGINE OIL 3 2 3 OIL FILTER 3 3 4 GEAR CASE OIL 3 4 5 SPARK PLUGS 3 6 6 VALVE CLEARANCE 3 9 7 FUEL STRAINER LOW PRESSURE SIDE 3 15 8 FUEL STRAINER HIGH PRESSURE SIDE 3 18 9 WATER SEPARATOR with WATER LEVEL SENSOR 3 19 10 IDLING 3 22 11 SHIFT CONTROL CABLE 3 24 12...

Page 3: ...5 109 IAB CONTROL VALVE INSPECTION 5 109 SHUTTER VALVE DIAPHRAGM INSPECTION 5 110 11 VAPOR SEPARATOR FUEL PUMP HIGH PRESSURE SIDE 5 111 12 SILENCER CASE THROTTLE BODY INTAKE MANIFOLD 5 128 13 FUEL INJECTOR PRESSURE REGULATOR 5 136 14 FUEL PUMP LOW PRESSURE SIDE 5 142 15 FUEL STRAINER LOW PRESSURE SIDE WATER SEPARATOR 5 144 16 EOP ENGINE OIL PRESSURE SWITCH HIGH PRESSURE SIDE 5 146 17 EOP ENGINE OI...

Page 4: ... 77 16 SHIM POSITION 2 14 84 17 BACKLASH ADJUSTMENT 2 14 85 18 ANODE METAL WATER SCREEN 14 88 19 EXTENSION CASE LOWER RUBBER MOUNT 14 89 20 OIL CASE 14 94 15 MOUNTING CASE STERN BRACKET SWIVEL CASE POWER TRIM TILT ASSEMBLY 15 1 1 MOUNTING CASE 15 2 2 STERN BRACKET SWIVEL CASE REMOVAL INSTALLATION 15 10 3 STERN BRACKET SWIVEL CASE POWER TRIM TILT ASSEMBLY 15 14 4 POWER TRIM TILT ASSEMBLY 15 36 5 AI...

Page 5: ...OP Engine Oil Pressure EX Exhaust F Front or Forward GND Ground IAB Intake Air Bypass IAC Idle Air Control IAT Intake Air Temperature I D Inside Diameter IG or IGN Ignition IN Intake INJ Injection L Left MAP Manifold Absolute Pressure MIL Malfunction Indicator Lamp O D Outside Diameter OP Optional Part PGM FI Programmed Fuel Injection P N Part Number Qty Quantity R Right SAE Society of Automotive ...

Page 6: ...s 234 kg 516 lbs 1 With propeller mounted Model BF150A Description code BANJ BAPJ BANJ BAPJ Types LC LD LCD XC XD XCC XCD Overall length 845 mm 33 3 in Overall width 580 mm 22 8 in Overall height 1 665 mm 65 6 in 1 790 mm 70 5 in Dry weight 1 220 kg 485 lbs 223 kg 492 lbs 226 kg 498 lbs Operating weight including oil 228 kg 503 lbs 231 kg 509 lbs 234 kg 516 lbs Model BF135A BF150A Types LC LD LCD ...

Page 7: ...BF135A BF150A OUTBOARD MOTORS It may be necessary to refer to this chart for reference purposes when reading this manual Model BF135A BF150A Types LC LD LCD XC XD XCC XCD Shaft length type L L L XL XL XL XL Remote control Control panel Counter rotation Power trim tilt ...

Page 8: ...ply system Programmed fuel injection Fuel injection system Electronic control Fuel injection nozzle Multi hole type Fuel pipe Rubber tubes Lubrication system Pressure lubrication by trochoid pump Lubrication capacity 7 35r 7 8 US qt 6 5 lmp qt with oil filter replacement 6 7r 7 1 US qt 5 9 lmp qt without oil filter replacement 6 5r 6 9 US qt 5 7 lmp qt Starting system Electric starter Stopping sys...

Page 9: ...1 4 2 DIMENSIONAL DRAWINGS Extra long shaft type 382 mm 15 0 in 30 845 mm 33 3 in 12 580 mm 22 8 in 1 665 mm 65 6 in 1 790 mm 70 5 in 508 mm 20 0 in 635 mm 25 0 in ...

Page 10: ...INV S 16 32 x 15T x 30 x 1 5 mm M18 x 1 5 28 5 mm 1 12 in 57 5 0 5 mm 2 26 0 02 in 56 5 mm 2 22 in 151 mm 5 9 in ø4 ø0 2 7 mm 0 3 in ø24 9 ø0 98 0 0 1 0 0 003 ø16 9 ø0 67 0 03 0 04 0 001 0 002 ø30 ø1 2 0 020 0 041 0 0008 0 0016 ...

Page 11: ...wered equipment up in the air Any time you lift an outboard motor with a hoist make sure that the hoist hook is securely attached to the outboard motor Make sure the engine is off before you begin any servicing procedures unless the instruction tells you to do otherwise This will help eliminate several potential hazards Carbon monoxide poisoning from engine exhaust Be sure there is adequate ventil...

Page 12: ...R PRODUCT IDENTIFICATION NUMBER 3 SERVICE RULES 1 Use genuine Honda or Honda recommended parts and lubricants or their equivalents Parts that do not meet Honda s design specifications may damage the unit 2 Use the special tools designed for the product 3 Install new gaskets O rings etc when reassembling 4 When torquing bolts or nuts begin with larger diameter or inner bolts first and tighten to th...

Page 13: ...uide clearance IN 0 030 0 055 0 0012 0 0022 0 08 0 003 EX 0 055 0 080 0 0022 0 0031 0 11 0 004 Valve seats Seat width IN EX 1 25 1 55 0 049 0 061 2 0 0 08 Seat installation height IN EX 44 0 44 6 1 73 1 76 Valve guides Guide I D IN EX 5 51 5 53 0 217 0 218 5 55 0 219 Guide extrusion amount IN 15 2 16 2 0 60 0 64 EX 15 5 16 5 0 61 0 65 Valve springs Free length IN 49 64 1 954 EX 49 64 1 954 Rocker ...

Page 14: ... sleeve I D A or I 87 01 87 02 3 4256 3 4260 87 07 3 4279 B or II 87 00 87 01 3 4252 3 4256 87 07 3 4279 Gap between upper and lower points 0 05 0 002 of sleeve I D Warpage 0 07 0 003 Max 0 10 0 004 Connecting Small end I D 23 969 23 982 0 9437 0 9442 rods Small end to piston pin clearance 0 005 0 015 0 0002 0 0006 0 02 0 001 Big end axial clearance 0 15 0 35 0 006 0 014 0 4 0 02 Connecting rod be...

Page 15: ...y side clearance 0 14 0 19 0 006 0 007 0 20 0 008 Vapor separator Float height 28 5 33 5 1 12 1 32 Fuel pump Discharge volume 45 mR 1 5 Us oz 1 6 Imp oz with pump operated for 2 sec at 12V or more Fuel line Fuel pressure kPa kgf cm2 psi 270 320 2 8 3 3 40 47 Alternator Brush length 10 5 0 41 8 4 0 33 Brush spring pressure 3 2 N 0 33 kgf 0 73 lbf Rotor coil resistance 2 9 Ω Slip ring O D 14 4 0 57 ...

Page 16: ...37 0 9843 24 966 0 9829 shaft LC LD XC and XD types At reverse bevel gear 24 987 25 000 0 9837 0 9843 24 966 0 9829 LCD XCC and XCD types At needle bearing 30 007 30 020 1 1814 1 1819 29 990 1 1807 Vertical Shaft O D at needle bearing 28 556 28 575 1 1242 1 1250 28 545 1 1238 shaft FRAME Unit mm in ...

Page 17: ...tensioner arm bolt M8 x 1 25 Special bolt 22 2 2 16 Exhaust camshaft sprocket bolt M10 x 1 25 72 7 3 53 VTC flange bolt M12 x 1 25 Special bolt 113 11 5 83 Camshaft holder bolt M8 x 1 25 22 2 2 16 M6 x 1 0 12 1 2 9 Camshaft collar bolt M14 x 1 0 Special bolt 39 4 0 29 CMP pulse plate bolt M14 x 1 0 Special bolt 39 4 0 29 Valve adjusting lock nut IN side M7 x 0 75 20 2 0 14 Valve adjusting lock nut...

Page 18: ...apor separator assembly bolt M8 x 1 25 26 2 7 20 Vapor separator stay bolt M8 x 1 25 26 2 7 20 Service check bolt M6 x 1 0 12 1 2 9 Vapor separator cover screw M5 screw 3 4 0 35 2 5 Water jacket cover screw M5 screw 3 4 0 35 2 5 Strainer cover screw M5 screw 3 4 0 35 2 5 Pump cover screw M5 screw 3 4 0 35 2 5 Pump harness assembly screw M4 screw 2 1 0 21 1 5 Float pin screw 2 1 0 21 1 5 Fuel pump ...

Page 19: ...nut M8 x 1 25 11 1 1 8 Alternator B terminal washer nut M6 x 1 0 8 0 8 5 8 Alternator fuse box B terminal washer nut M6 x 1 0 8 0 8 5 8 Alternator fuse box bolt M6 x 1 0 5 0 5 3 6 Fuse box bracket bolt M6 x 1 0 5 0 5 3 6 PGM FI main relay bolt M6 x 1 0 5 0 5 3 6 ECM bracket bolt M6 x 1 0 5 0 5 3 6 L R engine under cover screw M6 screw 4 5 0 45 3 3 Starter motor bolt M10 x 1 25 44 4 5 33 Item Threa...

Page 20: ...er mount center housing removal 21 Pilot 22 mm 07746 0041000 22 x 35 x 7 mm water seal installation 22 Driver 07749 0010000 Driver for 10 through 13 17 through 21 33 through 35 and 48 23 Valve spring compressor 07757 0010000 Valve keeper removal installation 24 Valve spring compressor attachment 07757 PJ10100 25 Valve seat cutter 45 35 mm 07780 0010400 Valve seat reconditioning IN 26 Valve seat cu...

Page 21: ...im tilt assembly blow pressure inspection 47 Oil pressure gauge joint B 07SPJ ZW10200 48 Oil seal driver attachment 96 07ZAD PNA0100 Crankshaft oil seal installation 49 VTEC air adapter 07ZAJ PNA0101 VTEC system VTEC valve inspection 50 VTEC air stopper 07ZAJ PNA0200 51 Air joint adapter 07ZAJ PNA0300 1 47 5 7 46 40 34 33 39 38 37 36 35 44 45 51 50 49 43 42 41 48 23 24 32 31 29 30 27 28 25 26 22 1...

Page 22: ...lash indicator tool 07SPJ ZW0030Z 21 Backlash indicator attachment 07SPK ZW10100 22 Shaft installer 15 x 370 mm 07VMF KZ30200 Needle bearing installation 23 Bearing driver attachment 37 mm 07ZMD MBW0200 Needle bearing outer race removal Special tools applicable to LC LD XC and XD types of gear case Tool name Tool number Application 24 Driver handle 480 mm 070GD 0010100 50 x 90 x 28 mm taper bearin...

Page 23: ... 40 and 41 43 Oil seal driver 65 mm 07JAD PL90100 50 x 90 x 20 mm radial ball bearing or installation 07JAD PL9A100 44 Backlash indicator tool 07SPJ ZW0030Z Reverse bevel gear backlash inspection 45 Backlash indicator attachment 07SPK ZW10100 46 Pin spanner wrench 110 mm 07WAA S1G0100 Bearing holder assembly removal installation 1 2 8 26 34 9 27 35 10 15 14 24 20 44 21 45 22 37 31 41 33 11 12 13 7...

Page 24: ...st ments Check valve clearance P 3 9 Check valve timing P 9 12 Check for loose cylinder head Check for damaged cylinder head gasket valves and valve seats Check for worn pistons piston rings and cylinders Remove the spark plugs and check for wet fouled electrodes Does not start Compression OK Perform ignition system troubleshooting P 2 25 Fuel flow restricted When gasoline overflow from the vapor ...

Page 25: ...re the cylinder compression 9 Check the compression on all cylinders CYLINDER COMPRESSION TEST 1 Move the remote control lever to the N Neutral position 2 Remove the clip of the emergency stop switch 3 Remove the engine cover and disconnect the fuel injector connectors of each cylinder 4 Disconnect the ignition coil connector of each cylinder and remove the spark plugs THROTTLE ARM COMPRESSION GAU...

Page 26: ...rform fuel supply system trouble shooting P 5 96 Idle control system faulty Perform idle control system trouble shooting P 5 93 Secondary air being sucked Loosely tightened IAC valve dam aged gasket Loosely tightened throttle body damaged seal ring Loosely tightened intake manifold damaged seal ring Damaged fuel injector seal ring Loosely tightened injector base damaged gasket Retighten the IAC va...

Page 27: ...el strainer P 3 15 Low pressure fuel system faulty Perform fuel supply system trouble shooting P 5 96 High pressure fuel system faulty Perform fuel supply system trouble shooting P 5 96 Valve clearance misadjusted Adjust the valve clearance P 3 9 Variable intake system faulty Perform variable intake system troubleshooting P 5 109 Neutral switch faulty BF150A only Replace the neutral switch P 17 11...

Page 28: ...Secondary air being sucked Loosely tightened IAC valve dam aged gasket Loosely tightened throttle body damaged seal ring Loosely tightened intake manifold damaged seal ring Damaged fuel injector seal ring Loosely tightened injector base damaged gasket Retighten the IAC valve Replace the gasket if damaged P 5 95 Retighten the throttle body Replace the seal ring if damaged P 5 132 Retighten the inta...

Page 29: ...ainer clogged Replace the low pressure fuel strainer P 3 15 Fuel tube faulty High pressure fuel system faulty Check for pinched or collapsed tube line and correct if necessary Check the air vent knob of the tank Open the air vent knob if it is closed Check the primer bulb for air leak age Replace if necessary Perform fuel supply system trouble shooting P 5 96 Propeller mismatched Excessive engine ...

Page 30: ... LOAD CHART on P 2 20 Turn the ignition switch ON Check whether the warning buzzer sounds twice Perform the following checks and repair if necessary Open in the wire between the MIL and ECM Blown MIL If there is no problem replace the ECM with a new one and recheck Does not sound NO NO NO NO NO Does not come ON YES YES YES YES Sounds YES Comes ON Check the power line of the main wire harness Is th...

Page 31: ...ON To A F SENSOR To ECM LAF To ECM FLR1 FLR2 Bu R To FUEL PUMP W W Bl Bu Bl To STARTER MAGNETIC SWITCH To ALTERNATOR OUTPUT TERMINAL To ECM LGP1 LGP2 To INJECTOR Y Bl To CKP SENSOR Y Bl To CMP SENSOR To IGNITION COIL To ALTERNATOR IGTERMINAL To INDICATOR LIGHT ACG MIL To IAB CONTROL VALVE To DATA LINK CONNECTOR POWER TILT SWITCH POWER TRIM TILT SWITCH No 3 10A FUSE No 1 30A FUSE No 7 30A FUSE W Y ...

Page 32: ...trim tilt relay Alternator detection terminal Ignition switch PGM FI main relay Warning buzzer Indicator light oil overheat Meters 4 15A ECM Fuel injector CMP sensor CKP sensor 5 10A Alternator IG terminal A F relay Indicator light MIL ACG IAB control valve data link connector 6 15A Ignition coil 7 30A PGM FI main relay FUSE BOX ALTERNATOR 90A FUSE ...

Page 33: ...on Check whether the engine turns with the ignition switch in the START posi tion Does not turn YES NO NO NO NO Replace the PGM FI main relay NO NO YES Engine turns To P 2 24 A In N Neutral position YES YES YES YES To P 2 24 B Check the battery for charging level Is the battery fully charged Perform charging system troubleshooting P 2 29 Check the battery terminals for con nection and corrosion Ar...

Page 34: ...2 23 B Replace the starter motor Charge the battery Repair or replace the wire har ness Replace the starter motor Check the ignition switch P 16 9 Is the ignition switch in good condi tion Replace the starter motor with a new one and recheck Does the starter motor turn Check the battery for charging level Is the battery fully charged Replace the starter motor with a new one and recheck Does the st...

Page 35: ...he spark plugs YES YES Wet fouled spark plugs YES NO Replace the spark plugs NO NO Replace the emergency stop switch YES YES Check for short in the black red wire of the emergency stop switch Is there continuity between the harness side black red terminal and the black ter minal Replace or repair the wire harness Install the new spark plugs and restart Does the engine start Check the emergency sto...

Page 36: ...e harness between the igni tion coil and the engine ground Check the engine ground and repair as nec essary No Check for open circuit in the ignition coil s power line 1 Disconnect the 3P connectors from each of the ignition coils 2 Turn the ignition switch ON Measure the voltage between the No 3 Yellow Green terminal of each har ness side 3P connector and the engine ground Is there the battery vo...

Page 37: ... of the respective harness side 3P connectors and the engine ground Is there continuity Replace the ignition coil Replace or repair the wire harness Short cir cuit in the wire harness between the ignition coil and the ECM Replace the ignition coil and recheck Does the engine start No 1 ignition coil Blue No 2 ignition coil Blue Black No 3 ignition coil White Green No 4 ignition coil Blue Red Ignit...

Page 38: ...the operation sound for 2 sec onds after the ignition switch is ON NO NO NO NO YES YES Yes To P 2 29 A YES To P 2 29 B Check for open circuit in the fuel pump ground line 1 Turn the ignition switch OFF and disconnect the fuel pump 2P con nector 2 Check for continuity between the No 2 Black White terminal of the harness side 2P connector and the engine ground Is there continuity Replace or repair t...

Page 39: ...t the main relay 2P connector 2 Check for continuity between the No 1 Blue Red terminal of the harness side main relay 2P con nector and the No 1 Blue Red terminal of the fuel pump 2P con nector Is there continuity Replace or repair the wire har ness Open circuit in the fuel pump power line YES Substitute a known good ECM and recheck YES Check the high pressure fuel system P 5 96 Is the high press...

Page 40: ...tor 4P connector and the engine ground Is there the battery voltage with the ignition switch ON Replace or repair the wire harness Open in the wire between the alternator and the igni tion switch NO NO Check for open circuit in the IG line 1 Turn the ignition switch OFF and discon nect the alternator 4P connector 2 Measure the voltage between the No 2 Yellow Red terminal of the alternator 4P conne...

Page 41: ... the wire har ness Open in the wire between the ECM and alter nator Substitute a known good ECM and recheck Check for open circuit in the wire harness White Blue between the ECM and the alternator Is the wire harness normal Turn the ignition switch ON Does the alternator indicator lightcome ON NO NO Check for open circuit in the L line 1 Stop the engine and discon nect the alternator 4P con nector...

Page 42: ...er level sensor detects the condition and transmits the signal to the ECM to sound the warning buzzer MIL WARNING SYSTEM The MIL indicator light comes ON and the buzzer sounds intermittent prolonged sound when the ECM detects a prob lem by its diagnostic function WARNING SYSTEM Condition Indicator light Warning indicator light Warning buzzer Oil indicator Overheat ACG MIL light Green indicator ind...

Page 43: ...the ignition switch OFF and disconnect the remote control cable 14P connec tor 2 Check for continuity bet ween the No 7 Yellow Green terminal and the engine ground Is there continuity Replace the buzzer Add the oil to the correct level Check the indicator light Is the overheat indicator light ON NO ON No Stop the engine and check the oil level Is the oil level correct Check the oil indicator light...

Page 44: ... with the engine idling NO Check for short in the high pres sure side oil pressure switch line 1 Turn the ignition switch OFF 2 Check for continuity between the No 1 Green Red termi nal of the harness side oil pressure switch 2P connec tor and the engine ground Is there continuity Oil pressure switch 2P connector Viewing from terminal side Snap the engine 4 000 min 1 rpm or above under no load and...

Page 45: ...re switch to the specified torque TORQUE 8 3 N m 0 85 kgf m 6 1 lbf ft Perform the following checks and repair or replace as nec essary Clogged oil strainer Clogged oil filter Faulty oil pump Clogged oil passage No Substitute a known good ECM and recheck Yes No From P 2 34 OIL PRESSURE GAUGE SET 07506 3000001 Oil pressure switch is faulty Check the oil pressure Is the oil pressure within the speci...

Page 46: ...port continuously NO YES From P 2 33 NO NO NO YES The system is restored to nor mal operation Perform ECT sensor 2 3 and 4 troubleshooting P 5 51 52 and 55 or 5 84 86 and 89 Replace the thermostat Stop the engine and check the water screen Is the water screen clogged NO YES Put the outboard motor into gear and let the engine idle for a few minutes to cool it down Do the overheat indicator light go...

Page 47: ...icator light power line 1 Turn the ignition switch OFF and disconnect the indicator light 3P connector 2 Turn the ignition switch ON Measure the voltage bet ween the No 3 Yellow Black terminal of the harness side 3P connector and the engine ground Is there the battery voltage Harness side connector Viewing from terminal side Is the alternator fuse 90A nor mal YES Perform alternator trouble shootin...

Page 48: ...een Red terminal of the water level switch harness side 2P connector and the engine ground Is there continuity Drain the water from the water separator and or the low pressure fuel strainer P 3 15 YES Replace the water level sensor in the water separator Replace or repair the wire harness Short in the wire between the water level sensor and ECM Disconnect the water level sensor 2P con nector Does ...

Page 49: ... 3 Shift cable misadjusted Adjust P 3 25 Shift detent arm damaged Replace P 17 12 Shift rod and shift rod A bent or twisted Replace P 14 4 9 43 and 48 Shift shaft A and or B bent Replace P 15 3 Shift arm damaged Replace P 17 11 In gear case assembly Clutch shifter damaged Shift slider damaged Replace P 14 18 and 57 ...

Page 50: ...O ring and oil seal at the leaking point Low level Add the oil to the specified level P 15 47 Check the manual valve for looseness OK No air Power trim tilt assembly faulty Repair the faulty part s by referring to POWER TRIM TILT ASSEMBLY QUICK REFERENCE CHART P 2 43 Air in the system Bleed air from the system P 15 48 OK Check for air in the system Check the oil level with the piston rods fully ex...

Page 51: ...ssembly Abnormal Replace the motor assembly or gear pump assembly Check for oil leakage from the power trim tilt assembly Not leaking Normal Replace the power trim tilt assembly Low level Add the oil to the specified level P 15 47 Normal Check the oil level P 15 47 No air in the system Air in the system Bleed air from the system P 15 48 Check for air in the system Check for oil leakage from the cy...

Page 52: ...e motor assem bly Check for oil inside the motor Disassemble the motor and replace the faulty parts Replace the power trim tilt relay Connect the 12V battery directly to the motor terminals and check whether the motor turns Replace or repair the wire harness Does not turn Open circuit Overheats Abnormal Oil Abnormal Abnormal No open circuit Does not overheat Normal No oil Turns Normal Normal Check...

Page 53: ...r mal clean and install on the piston rod B properly Check the backup ring for damage and replace if necessary Check the O ring surface for damage and replace if necessary If the backup ring and O ring are nor mal clean and install on the free piston properly Check the ball seat and the neighboring area for damage and replace the free piston as an assembly if necessary Do not disassemble the free ...

Page 54: ...ER CHAMBER CHECK VALVE UPPER CHAMBER SPOOL VALVE MOTOR DUST SEAL O RING OIL ATF SHOCK RELIEF VALVE O RING BACKUP RING O RING BACKUP RING O RING BACKUP RING CHECK VALVE O RING FREE PISTON PUMP ASSEMBLY PISTON ROD ASSEMBLY LOWER CHAMBER SPOOL VALVE UP RELIEF VALVE DOWN RELIEF VALVE ...

Page 55: ...GINE COOLANT TEMPERATURE SENSOR 1 2P CONNECTOR 9 EOP ENGINE OIL PRESSURE SWITCH HIGH PRESSURE SIDE 2P CONNECTOR 10 EOP ENGINE OIL PRESSURE SWITCH LOW PRESSURE SIDE 12 ECT ENGINE COOLANT TEMPERATURE SENSOR 3 11 COVER LOCK CABLE B 2 HARNESS BAND CLIP 1 WATER RELIEF TUBE A Clamp the alternator fuse cable and the main wire harness 7 HARNESS BAND CLIP Connect the cable to the alternator B terminal as s...

Page 56: ...TOR 10 EOP ENGINE OIL PRESSURE SWITCH LOW PRESSURE SIDE 13 ECT ENGINE COOLANT TEMPERATURE SENSOR 3 3 ECT ENGINE COOLANT TEMPERATURE SENSOR 4 2P CONNECTOR 2 ECT ENGINE COOLANT TEMPERATURE SENSOR 4 18 HARNESS BAND CLIP 15 MAIN WIRE HARNESS Clamp the main wire harness and the ECT sensor 3 wire as shown 1 HARNESS BAND CLIP 1 3 MAIN WIRE HARNESS 1 1 ECT ENGINE COOLANT TEMPERATURE SENSOR 3 WIRE Clamp th...

Page 57: ... HARNESS BAND CLIP 5 ECT ENGINE COOLANT TEMPERATURE SENSOR 4 2P CONNECTOR 6 ECT ENGINE COOLANT TEMPERATURE SENSOR 4 4 MAIN WIRE HARNESS Clamp the VTEC solenoid valve wire BF150A only and the A F sensor wire as shown 3 HARNESS BAND CLIP 3 1 A F AIR FUEL RATIO SENSOR 4P CONNECTOR 3 3 VTEC SOLENOID VALVE WIRE BF150A only 3 2 INSIDE ...

Page 58: ...TION SENSOR 3P CONNECTOR 4 ECT ENGINE COOLANT TEMPERATURE SENSOR 1 10 CKP CRANKSHAFT POSITION SENSOR 6 EOP ENGINE OIL PRESSURE SWITCH HIGH PRESSURE SIDE 2P CONNECTOR 7 EOP ENGINE OIL PRESSURE SWITCH LOW PRESSURE SIDE 11 HARNESS BAND CLIP 3 MAIN WIRE HARNESS Clamp the alternator fuse cable and the main wire harness as shown 8 HARNESS BAND CLIP ...

Page 59: ...STARTER CABLE 7 MAIN WIRE HARNESS 12 STARTER CABLE 1P CONNECTOR WHITE CABLE 3 ALTERNATOR FUSE BOX 90A 20 POWER TILT SWITCH 3P CONNECTOR 19 POWER TILT SWITCH WIRE 18 STARTER CABLE 3P CONNECTOR 4 WIRE HARNESS CLIP 1 HARNESS BAND CLIP 26 ALTERNATOR FUSE CABLE WHITE CABLE 2 FUSE BOX Clamp the alternator fuse cable and the main wire harness 9 HARNESS BAND CLIPS 8 OFFSET HARNESS BAND 10 A F AIR FUEL RAT...

Page 60: ... FI main relay connector wire as shown 9 WIRE HARNESS CLIP Clamp the alternator fuse cable PGM FI main relay wire and the power tilt switch wire at the grommet 6 ELECTRIC PART CASE Set the alternator fuse cable and the starter cable in the cable holder of the electric part case as shown 15 ALTERNATOR FUSE CABLE WHITE CABLE 5 ALTERNATOR FUSE CABLE 2 ALTERNATOR FUSE BOX 90A 8 POSITIVE STARTER CABLE ...

Page 61: ... CABLE 11 8 mm WASHER NUT 2 12 8 mm WASHER 7 ALTERNATOR FUSE CABLE 7 ALTERNATOR FUSE CABLE 14 STARTER MOTOR B TERMINAL 1 POWER TILT SWITCH 3P CONNECTOR 4 STARTER CABLE 3 HARNESS BAND CLIP 4 STARTER CABLE 7 ALTERNATOR FUSE CABLE 10 PGM FI MAIN RELAY CONNECTOR 8 WIRE HARNESS CLIP Clamp the alternator fuse cable PGM FI main relay wire and the power tilt switch wire at the grommet 9 POWER TILT SWITCH ...

Page 62: ...KET A Clamp the alternator fuse cable and the starter cable as shown 8 WIRE HARNESS CLIP Clamp the alternator fuse cable and the starter cable and check that the cables do not interfere with the shift arm 7 NEGATIVE STARTER CABLE Connect the negative starter cable by pushing the starter cable negative terminal against the projection on the crankcase 7 1 STARTER CABLE NEGATIVE TERMINAL 7 2 PROJECTI...

Page 63: ...E 10 WHIT TAPE 12 REMOTE CONTROL CABLE GROMMET 12 REMOTE CONTROL CABLE GROMMET 9 FRONT BRACKET 9 FRONT BRACKET 11 STARTER CABLE Install aligning the end of the white tape on the starter cable with the end of the under cover front bracket 13 TIE WIRES Install the remote control cable and the indicator light wire with the tie wire on the respective cables set against the remote control cable grommet...

Page 64: ...L CABLE 4 REMOTE CONTROL CABLE 14P CONNECTOR 2 REMOTE CONTROL CABLE Throttle side 13 POWER TILT MOTOR 2P CONNECTOR 11 COVER LOCK CABLE A 6 SPEED SENSOR TUBE A 6 SPEED SENSOR TUBE A 3 HARNESS BAND CLIP 3 HARNESS BAND CLIP 3 HARNESS BAND CLIP 1 REMOTE CONTROL CABLE Shift side 2 REMOTE CONTROL CABLE Throttle side 5 MAIN WIRE HARNESS 9 TP THROTTLE POSITION SENSOR 12 TRIM ANGLE SENSOR 3P CONNECTOR 7 PO...

Page 65: ...reen white wires to the upper frame ground terminal and the green blue black white and the green black wires to the lower frame ground terminal Install by pushing the frame ground terminals against the corresponding projections on the crankcase 3 HARNESS BAND CLIP 3 HARNESS BAND CLIP 3 HARNESS BAND CLIP 18 CLIP A 6 COVER LOCK CABLE A 1 1 PROJECTION 1 1 PROJECTION 1 2 FRAME GROUND TERMINAL 1 2 FRAM...

Page 66: ... motor wire trim angle sensor wire and the speed sensor tube A Install the undercase grommet C aligning the taped ends of the power tilt motor wire and the trim angle sensor wire with the end of the undercase grommet C Check that the wires and tube are not interfering with the front lock of the under cover front bracket 6 HARNESS CLIP Clamp the main wire harness and the water level sensor wire at ...

Page 67: ...s as shown 1 POWER TILT RELAY GROUND TERMINAL Install pushing the ground terminal against the projection on the crankcase 1 2 PROJECTION 1 1 GROUND TERMINAL 16 IAT INTAKE AIR TEMPERATURE SENSOR 2P CONNECTOR 17 IAT INTAKE AIR TEMPERATURE SENSOR 15 MAP MANIFOLD ABSOLUTE PRESSURE SENSOR 3P CONNECTOR 14 MAP MANIFOLD ABSOLUTE PRESSURE SENSOR 12 IAC IDLE AIR CONTROL VALVE 11 IAC IDLE AIR CONTROL VALVE 2...

Page 68: ...control valve wire as shown 3 3 IAB IDLE AIR BYPASS CONTROL VALVE WIRE 13 IAB IDLE AIR BYPASS CONTROL VALVE WIRE 3 4 BARO BAROMETRIC PRESSURE SENSOR WIRE 3 2 MAIN WIRE HARNESS 3 1 ENGINE SIDE 6 4 BARO BAROMETRIC PRESSURE SENSOR WIRE 6 2 MAIN WIRE HARNESS 6 1 ENGINE SIDE 8 ECT ENGINE COOLANT TEMPERATURE SENSOR 2 12 WIRE HARNESS CLIP Clamp the main wire harness and the overheat sensor 1 wire 12 1 OV...

Page 69: ...E 2 1 JOINT CONNECTOR 2 WIRE 8 JOINT CONNECTOR 2 WIRE 9 JOINT CONNECTOR 1 WIRE 7 1 JOINT CONNECTOR 1 7 3 JOINT CONNECTOR 2 2 4 MAIN WIRE HARNESS 2 2 ENGINE SIDE 5 HOSE CLIP Clamp the main wire harness and the pressure regulator return hose 4 TUBE CLAMP D10 7 Check that the main wire harness does not interfere with the tube clamp D10 7 5 3 PRESSURE REGULATOR RETURN HOSE 3 PRESSURE REGULATOR RETURN ...

Page 70: ...NT TEMPERATURE SENSOR 3 2P CONNECTOR 12 CMP SENSOR 3P CONNECTOR 13 COVER LOCK CABLE B 14 COVER LOCK CABLE A 1 HARNESS BAND CLIP 1 HARNESS BAND CLIP 17 No 1 FUEL INJECTOR 2P CONNECTOR 1 HARNESS BAND CLIP 2 MAIN WIRE HARNESS 2 MAIN WIRE HARNESS 16 No 2 FUEL INJECTOR 2P CONNECTOR 15 No 3 FUEL INJECTOR 2P CONNECTOR 11 No 4 IGNITION COIL 3P CONNECTOR 10 No 4 IGNITION COIL 19 CMP CAMSHAFT POSITION SENSO...

Page 71: ...8 COVER LOCK CABLE B 10 COVER LOCK CABLE A 2 HOSE CLAMP Set the fuel hose high pressure side in the clamp of the larger diameter side and the main wire harness in the smaller diameter side Clamp the fuel hose high pressure side at the left hand side to the marked point 2 1 ENGINE SIDE 2 3 FUEL HOSE HIGH PRESSURE SIDE 2 3 FUEL HOSE HIGH PRESSURE SIDE 11 FUEL HOSE HIGH PRESSURE SIDE 2 5 MARKING 2 4 ...

Page 72: ...AL TUBE Wind the spiral tube around the power tilt motor wire trim angle sensor wire and the speed sensor tube A 11 WIRE HARNESS CLIP Clamp the power tilt motor wire trim angle sensor wire and the speed sensor tube A Avoid clamping on the spiral tube 13 UNDERCASE GROMMET C INSTALLATION P 2 56 12 14 mm CLIPS INSTALLATION P 2 63 9 CABLE CLIP 8 COVER LOCK CABLE A 3 HARNESS CLIP Clamp the main wire ha...

Page 73: ...the speed sensor tube B through the motor cord bushing Align the tape end of the power tilt motor wire with the end of the motor cord bushing 5 1 TRIM ANGLE SENSOR WIRE 5 2 SPEED SENSOR TUBE A 6 SPEED SENSOR TUBE B 5 3 POWER TILT MOTOR WIRE 5 4 TAPE 1 5 TAPE 1 5 TAPE 7 WIRE HARNESS CLIP Clamp the power tilt motor wire trim angle sensor wire and the speed sensor tube A Avoid clamping on the spiral ...

Page 74: ...OLENOID SWITCH 3 WARNING BUZZER 5 REMOTE CONTROL CABLE B 5 REMOTE CONTROL CABLE B 5 REMOTE CONTROL CABLE B 1 Power trim tilt switch wire routing when the remote control lever is installed as shown in the drawing A 2 Power trim tilt switch wire routing when the remote control lever is installed as shown in the drawing B 1 4 IGNITION SWITCH 1 View from ignition switch side 5 REMOTE CONTROL LEVER 2 8...

Page 75: ...2 65 Control panel 3 INDICATOR LIGHT OIL PRESSURE LIGHT OVERHEAT LIGHT 1 EMERGENCY STOP SWITCH 5 WIRE HARNESS BAND 2 IGNITION SWITCH 6 SWITCH PANEL HARNESS CONNECTION P 16 8 4 WARNING BUZZER ...

Page 76: ... the horizontal line After installation check the tube for twist bend etc 6 WATER RELIEF TUBE B Install at 33 from the horizontal line After installation check the tube for twist bend etc 8 TUBE CLAMP D25 0 Install at 8 mm 0 3 in from the tube end 8 TUBE CLAMP D25 0 Install at 8 mm 0 3 in from the tube end 1 2 WATER RELIEF TUBE A 6 2 WATER RELIEF TUBE B 12 WATER TUBE CLAMP INSTALLATION P 2 45 7 WA...

Page 77: ...MP D25 0 Install the tube clamp with the lugs facing in the direction shown 3 TUBE CLAMP D10 5 Install with the lugs facing down 3 TUBE CLAMP D10 5 Install with the lugs facing down 6 TUBE CLAMP D10 5 6 TUBE CLAMP D10 5 6 TUBE CLAMP D10 5 2 1 WATER RELIEF TUBE A 2 2 Cylinder head cover viewed from the front ...

Page 78: ... CLAMPS D10 5 1 TUBE CLAMPS D10 5 3 7 x 160 mm TUBE 6 7 x 40 mm TUBE 4 WATER RELIEF TUBE C 8 12 mm TUBE CLIP B1 8 12 mm TUBE CLIP B1 2 TUBE CLAMP D10 5 2 TUBE CLAMP D10 5 2 TUBE CLAMP D10 5 9 8 x 300 mm TUBE 9 8 x 300 mm TUBE 7 7 x 200 mm TUBE 7 7 x 200 mm TUBE ...

Page 79: ...ERCASE GROMMET C 2 FUEL TUBE A 2 FUEL TUBE A 1 4 x 7 x 160 mm VINYL TUBE 8 3 5 x 430 mm FUEL TUBE Set in the recess in the under cover front bracket 5 4 x 7 x 160 mm VINYL TUBE Insert into the hole in the under cover front bracket securely 6 RECESS 7 HOLE ...

Page 80: ... 70 6 FUEL TUBE HOLDER 5 14 mm FUEL TUBE CLIP 1 WATER SEPARATOR with WATER LEVEL SENSOR 4 FUEL TUBE A 6 FUEL TUBE HOLDER 5 14 mm FUEL TUBE CLIP 4 FUEL TUBE A 3 FUEL TUBE C 2 TUBE CLIP B12 2 TUBE CLIP B12 ...

Page 81: ...onnect the pressure regulator control tube aligning the marked part on the tube with the end of the 3 5 mm tube clamp 10 PRESSURE REGULATOR RETURN HOSE 13 HOSE CLAMP Set the air vent tube A in the clamp of the larger diameter side and the pressure regulator return hose in the smaller diameter side 16 PIPE CLAMP Set the air vent tube A in the clamp of the larger diameter side and the air vent tube ...

Page 82: ...ITE MARK 4 3 14 mm FUEL TUBE CLIP 8 14 mm FUEL TUBE CLIP Clamp the fuel tube B Check the fuel tube B protection tube for protrusion from the end of the 14 mm fuel tube clip The protection tube should protrude 2 mm 0 1 in max from the clip 8 1 FUEL TUBE B 12 FUEL TUBE D 7 FUEL TUBE B 7 FUEL TUBE B 6 1 2 mm 0 1 in MAX 8 3 14 mm FUEL TUBE CLIP 6 14 mm FUEL TUBE CLIP 11 14 mm FUEL TUBE CLIP Clamp the ...

Page 83: ...UEL TUBE E 1 TUBE CLIP 17 WATER TUBE F 19 7 x 400 mm TUBE 5 SENSOR HOSE CLIP Clamp the fuel hose high pressure side and the fuel tube B 15 SENSOR HOSE CLIP Clamp the fuel tube B and fuel tube E Install the sensor hose clip aligning with the end of the protection tube on the fuel tube E 16 AIR VENT TUBE A 2 HOSE CLAMP 3 FUEL HOSE HIGH PRESSURE SIDE 15 4 PROTECTION TUBE 15 2 SENSOR HOSE CLIP 15 3 FU...

Page 84: ... the oil tube installation part with the projection of the oil tube Install the tube clamp D32 5 with the lugs in the position shown 3 VAPOR CHAMBER 9 3 OIL TUBE 9 1 PROJECTION 9 1 PROJECTION 9 4 TUBE CLAMP D32 5 8 TUBE CLAMP D32 5 9 2 LUGS 12 TUBE CLIP Install with the lugs facing down 12 2 TUBE CLIP 12 3 LUGS 6 TUBE CLIP Clamp the air vent tube E and the fuel hose high pressure side as shown 1 H...

Page 85: ...L STRAINER 6 TUBE CLIP B12 3 WATER SEPARATOR with WATER LEVEL SENSOR 10 FUEL TUBE E 14 7 x 400 mm TUBE 11 WATER TUBE F 13 WATER CHECK GROMMET 17 14 mm FUEL TUBE CLIP 16 FUEL TUBE A 12 3 5 x 430 mm FUEL TUBE INSTALLATION P 2 69 7 MAIN WIRE HARNESS 1 4 x 7 x 160 mm VINYL TUBE INSTALLATION P 2 69 8 HOSE CLAMP INSTALLATION P 2 61 9 FUEL HOSE HIGH PRESSURE SIDE ...

Page 86: ...d bushing as shown Install the speed sensor tube B so that the distance between the end of the motor cord bushing and the end of the speed sensor tube B is 10 15 mm 0 4 0 6 in 3 1 SPEED SENSOR TUBE B 4 TUBE CLIP B8 3 1 SPEED SENSOR TUBE PLATE 2 SPEED SENSOR TUBE PLATE 15 20 mm 0 6 0 8 in 1 SPEED SENSOR TUBE B 7 MOTOR CORD BUSHING 8 1 MOTOR CORD BUSHING 8 1 MOTOR CORD BUSHING INSTALLATION P 2 63 8 ...

Page 87: ...s PROPELLER SHAFT DETENT ARM ROLLER NEUTRAL SWITCH COVER LOCK CABLE B CABLE END R SIDE LOCK MOUNTING PLATE THROTTLE PLATE THROTTLE ARM THROTTLE ARM LINK PIN SHIFT SLIDE PIVOT SHIFT PIVOT PLATE LINK PIN SHIFT LINK PIN Marine grease SHIFT ROD A VERTICAL SHAFT 1 2 3 4 5 6 ...

Page 88: ...8 FRONT ROCK CABLE FRONT ROCK COVER OPEN SHAFT COVER LOCK CABLE A B CABLE END L SIDE LOCK THROTTLE BODY Marine grease TILTING SHAFT TILTING SHAFT THREADS DETENT SPRING ROLLER TILTING BRACKET CAM 1 2 3 4 5 ...

Page 89: ...2 79 LOWER CYLINDER BUSHINGS COLLAR WAVE WASHERS UPPER CYLINDER BUSHING PIN SLIDING SURFACE OF THRUST RECEIVER COVER LOCK BOLTS SWIVEL CASE TILT STOPPER BEARING 1 3 4 5 2 ...

Page 90: ...etal Check 14 88 Lubrication Grease 2 2 2 77 Water separator Check 3 19 Fuel strainer Check 3 15 Replace Fuel strainer Replace 3 18 High pressure type Thermostat Check 8 3 Fuel line Check 5 104 Replace Every 2year Replace if necessary Battery and cable Check level tightness connection Bolt and nuts Check tightness Crankcase breather Check tube Cooling water Clean 3 passages Each use After use Firs...

Page 91: ...hange Drain the used oil while the engine is warm Warm oil drains quickly and completely 1 Remove the oil filler cap and the drain plug cover 2 Attach the drain plug cover to the oil drain guide of the oil case 3 Place a suitable oil container next to the outboard motor and remove the oil drain plug bolt Please dispose of used motor oil in a manner that is compatible with the environment We sugges...

Page 92: ...to tighten the filter an additional 7 8 turn TOOL Oil filter wrench 07HAA PJ70101 TORQUE 12 N m 1 2 kgf m 9 lbf ft 6 Refill the engine with the specified amount of the recommended oil as described in the oil change procedure Reinstall the oil filter cap and dipstick 7 Start the engine and check the leaks 8 Stop the engine and check the oil level as described on page 3 2 If necessary add oil to the...

Page 93: ... on assembly 2 Remove the oil level bolt and add the gear oil until it flows out of the oil level bolt hole Replace the O ring on assembly 3 Check for the metal particles on the magnet end of the oil drain bolt 4 If there are metal particles on the magnet end of the oil drain bolt disassemble the gear case assembly and check See section 14 5 After adding the gear oil apply clean engine oil to the ...

Page 94: ...s on the magnet end of the oil drain bolt disassemble the gear case assembly and check See section 14 5 Install a commercially available gear oil pump in the oil drain bolt hole and add gear oil until it flows out of the oil level bolt hole 6 After adding the gear oil apply clean engine oil to the new O rings and install them on the oil drain bolt and the oil level bolt Set the oil drain bolt and ...

Page 95: ...2 Set a screwdriver in the slot in the two mud guard clips at the top of the under cover grommet and raise the mud guard clips Remove the two mud guard clips 3 Detach the upper part of the under cover grommet 2 6 x 25 mm SOCKET BOLT 2 1 PHC COVER 5 UNDER COVER GROMMET 4 MUD GUARD CLIP 2 3 MUD GUARD CLIP 1 SCREWDRIVER 2 SLOT ...

Page 96: ...s excessively Do not drop the ignition coils and do not strike on the ignition coils either during removal installation of the coils Do not reuse the ignition coils when they are dropped 7 Clean any dirt from around the spark plug bases NOTICE 8 Remove the spark plugs using a spark plug wrench 6 6 x 25 mm SOCKET BOLT 2 7 IGNITION COIL 3P CONNECTOR 5 IGNITION COIL 1 No 1 IGNITION COIL 2 No 2 IGNITI...

Page 97: ... reusing a plug tighten 1 8 1 4 turn after the plug seats TORQUE 18 N m 1 8 kgf m 13 lbf ft A loose spark plugs can become very hot and can damage the engine Overtightening the spark plugs can damage the threads in the engine 6 Install the ignition coils and tighten each with the 6 x 25 mm socket bolt securely P 3 7 7 Connect the ignition coil 3P connector to each ignition coil and install the PHC...

Page 98: ...ips 4 Remove the under cover grommet 5 Remove the PHC cover P 3 6 Remove the four ignition coils and the four spark plugs P 3 7 Remove the L R engine under covers P 4 9 1 R SIDE COVER BRACKET 6 x 22 2 1 CYLINDER HEAD COVER 2 BREATHER TUBE 3 MAIN WIRE HARNESS 6 Remove the two 6 x 22 mm flange bolts and remove the R side cover bracket from the engine assembly 7 Disconnect the breather tube and main ...

Page 99: ...o prevent the gasoline from leaking 10 Move the water relief tube A from your side of the projection on the cylinder head cover to the other side 2 MOUNTING CASE 1 OIL TUBE 1 WATER RELIEF TUBE A 3 CYLINDER HEAD COVER 2 PROJECTION 1 TUBE CLIP Commercially available 2 FUEL TUBE B 4 FUEL TUBE D 3 FUEL PUMP Gasoline is highly flammable and explosive You can be burned or seriously injured when handling...

Page 100: ...the harness band clip that clamps the main wire harness from the silencer duct assembly 13 Remove the breather tube from the 18 5 mm clamp and the guide of the silencer duct assembly 3 6 mm HEX CAP NUT 6 2 HEAD COVER WASHER 6 1 CYLINDER HEAD COVER 1 SILENCER DUCT ASSEMBLY 5 3 5 mm TUBE CLIP 5 3 5 mm TUBE CLIP 4 PRESSURE REGULATOR CONTROL TUBE 2 18 5 mm CLAMP 8 GUIDE 7 MAIN WIRE HARNESS 6 HARNESS B...

Page 101: ... bolt on the crankshaft pulley as shown Turn the crankshaft pulley clockwise 16 Align the cutout in the crankshaft pulley with the mark on the chain case Do not turn the crankshaft pulley counterclockwise 6 x 25 4 1 6 mm WASHER 4 2 SILENCER DUCT ASSEMBLY 3 CRANKSHAFT PULLEY 3 CRANKSHAFT PULLEY 2 16 x 49 mm WASHER BOLT 1 WRENCH 4 CUTOUT 5 CHAIN CASE 6 MARK ...

Page 102: ...djustment is necessary loosen the valve adjusting lock nut while holding the valve adjusting screw with a screwdriver 20 Insert a feeler gauge between the intake exhaust side rocker arm valve adjusting screw and the valve stem end 21 Adjust the intake and exhaust valve clearances by turning the valve adjusting screw 22 After adjustment secure the valve adjusting screw and loosely tighten the lock ...

Page 103: ... piston of each cylinder at the top dead center of its compression stroke Repeat the procedure from step 18 through step 23 3 No 2 PISTON AT TOP DEAD CENTER OF COMPRESSION STROKE 1 No 3 PISTON AT TOP DEAD CENTER OF COMPRESSION STROKE 2 No 4 PISTON AT TOP DEAD CENTER OF COMPRESSION STROKE 5 INTAKE SIDE No 1 No 2 No 3 No 4 No 1 No 2 No 3 No 4 4 EXHAUST SIDE ...

Page 104: ...with the end of the 3 5 mm tube clip P 2 70 29 Set the main wire harness harness band clip on the silencer duct assembly 30 Install the cylinder head cover P 10 40 7 FUEL STRAINER LOW PRESSURE SIDE Inspection 1 Remove the engine cover P 4 2 2 Visually check the fuel strainer cup low pressure side for water or foreign material in the cup Check the fuel strainer for contamination 3 If there is water...

Page 105: ...ent the gasoline from leaking Removal Disassembly Cleaning 1 Remove the three 5 x 12 mm screws from the fuel strainer body then remove the plate and the fuel strainer cup 2 Clean the water or sediment in the cup and if necessary replace the strainer 3 Replace the O ring with a new one on assembly Assembly 1 Install a new fuel strainer on the fuel strainer body 2 Set a new O ring on the fuel strain...

Page 106: ...ith the center of the strainer suspension as shown 7 Connect the fuel tube C to the mark side of the fuel strainer Connect the fuel tube E to the mark side of the fuel strainer After connecting the tubes check for gasoline leakage 8 Install the engine cover P 4 2 4 STRAINER SUSPENSION 3 FUEL STRAINER STAY 1 FUEL STRAINER STAY 1 FUEL STRAINER BODY 2 PROJECTIONS 5 MARK 2 MARK 4 FUEL TUBE C 3 FUEL TU...

Page 107: ...n the strainer cover 2 Install the spring strainer and washer in the case then install the strainer cover 3 Tighten the three screw washers to the specified torque TORQUE 3 4 N m 0 35 kgf m 2 5 lbf ft 4 After tightening the screw washers check for gasoline leakage 5 Set a new sealing washer on the service check bolt and tighten the service check bolt to the specified torque TORQUE 12 N m 1 2 kgf m...

Page 108: ... 1 Remove the engine cover P 4 2 2 Check the water separator for water accumulation or sediment If water or sediment is found or the water filled alert buzzer is sound remove the water separator as follows Removal Cleaning Turn the ignition switch to the OFF position disconnect the battery negative cable then positive cable 1 Open the harness clip Remove the water level sensor 2P connector from th...

Page 109: ...if it is mounted and check for continuity between the 2P connecter terminals There must be no continuity between the terminals 2 With the water separator cup removed hold the cup upside down and check for continuity between the 2P connector terminals There must be continuity between the terminals 3 If there is any abnormality during the check replace the water separator cup Assembly 1 Set a new O ...

Page 110: ...the center of the strainer suspension as shown 6 Connect the fuel tube A to the mark side of the water separator with water level sensor Connect the fuel tube C to the mark side of the water separator with water level sensor After connecting the tubes check for gasoline leakage 3 STRAINER SUSPENSION 7 STRAINER SUSPENSION 4 FUEL STRAINER STAY 3 FUEL STRAINER STAY 1 WATER SEPARATOR BODY 2 PROJECTION...

Page 111: ...hometer KOWA KEK 8 MT600 or the HDS Honda Diagnostic System How to connect the digital tachometer KOWA KEK 8 MT600 1 Disconnect the engine speed check connector Blue connector 2P connector 2 Connect the 2P connector of the cable that is included in the digital tachometer kit KOWA KEK 8 MT600 to the engine side 2P connector 1 ELECTRIC PART COVER 2 CABLE included in digital tachometer kit 1 ENGINE S...

Page 112: ...ngine under no load until the engine speed stabilizes and check the idling speed If the idle speed is out of the specification adjust the idle P 5 94 When the idle speed is outside the specification or when a problem symptom shown on the Idle Control System Troubleshooting Guide P 5 93 appears perform the adjustment 6 Install the engine cover P 4 2 Specified idle speed 750 50 min 1 rpm At neutral ...

Page 113: ...lat part of the detent arm 3 If the center of the neutral switch end does not align with the center of the flat part of the detent arm check the detent arm for deformation and damage Replace the detent arm with a new one if necessary P 17 13 If the detent arm roller is not in the groove in the shift arm adjust P 3 25 2 NEUTRAL SWITCH END 1 FLAT PART OF DETENT ARM 2 NEUTRAL SWITCH END 1 FLAT PART O...

Page 114: ... Move the remote control lever back and forth several times to check that the detent arm roller is in the groove in the shift arm securely Check that the center of the neutral switch end aligns with the center of the flat part of the detent arm Tighten the lock nut securely If the detent arm roller is not in the groove in the shift arm readjust 6 After adjustment install the front separate cover P...

Page 115: ...sition 1 THROTTLE CAM 2 STOPPER FULL OPEN SIDE 3 1 mm 0 04 in OR BELOW 1 THROTTLE CAM 3 STOPPER FULL CLOSE SIDE 2 1 mm 0 04 in OR BELOW 12 THROTTLE CONTROL CABLE THROTTLE LINK Inspection 1 Remove the engine cover P 4 2 Remove the front separate cover P 4 7 2 Move the remote control lever to the F Forward full open position If it is hard to move the remote control lever to the F Forward position wi...

Page 116: ... securely Throttle cam not in full open position Perform this adjustment with the remote control cable throttle side installed on the throttle arm Be sure that the throttle arm is in contact with the full open side stopper 1 Remove the throttle rod linkage pivot from the throttle plate and loosen the linkage pivot lock nut 2 With the throttle arm in contact with the full open side stopper turn the...

Page 117: ...emote control lever for smooth operation If the lever movement is too light or too heavy adjust the friction 2 Adjust by turning the friction adjusting bolt right or left 14 ALTERNATOR BELT Inspection 1 Remove the engine cover P 4 2 Remove the silencer duct assembly P 3 11 and 12 2 Check the alternator belt for wear and damage Replace the alternator belt if necessary P 3 29 3 Check the alternator ...

Page 118: ...ion loosen the 10 x 80 mm flange bolt and the 8 mm flange nut and adjust the belt tension or deflection by turning the special adjusting bolt right or left 2 After adjustment tighten the 8 mm flange nut and the 10 x 80 mm flange bolt in this order to the specified torque TORQUE 8 mm flange nut 26 N m 2 7 kgf m 20 lbf ft 10 x 80 mm flange bolt 44 N m 4 5 kgf m 33 lbf ft 3 After tightening the bolt ...

Page 119: ...nstall the engine cover P 4 2 1 8 mm FLANGE NUT 2 SPECIAL ADJUSTING BOLT 3 ALTERNATOR ASSEMBLY 10 x 80 1 ALTERNATOR BELT 2 CRANKSHAFT PULLEY 3 ALTERNATOR PULLEY 3 Remove the alternator belt by removing it from the alternator pulley first then from the crankshaft pulley Do not contaminate the alternator belt with oil or grease Do not bend the alternator belt Store the belt by hanging it on the wall...

Page 120: ...1 4 ENGINE COVER COVER LOCK 1 ENGINE COVER 2 FRONT SEPARATE COVER 3 L R ENGINE UNDER COVERS 4 UNDER COVER FRONT BRACKET L R SIDE COVER BRACKETS 4 5 N m 0 45 kgf m 3 3 lbf ft 4 5 N m 0 45 kgf m 3 3 lbf ft ...

Page 121: ...bly Front side hook bracket only Remove the two 6 x 20 mm socket bolts and remove the hook bracket assembly Rear L R side hook brackets only 2 Remove the three 6 5 x 10 x 11 5 mm distance collars from the engine cover Front side hook bracket only Remove the four 6 5 x 10 x 11 5 mm distance collars from the engine cover Rear L R side hook brackets only 3 6 5 x 10 x 11 5 mm DISTANCE COLLAR 4 Rear L ...

Page 122: ...CE COLLAR 3 1 6 x 16 mm SOCKET BOLT 2 6 x 20 mm SOCKET BOLT 7 LOCK ADJUSTING SPRING 4 COVER LOCK BOLT 10 6 mm HEX NUT 8 HOOK BRACKET L R SIDES 2 6 5 x 10 x 11 5 mm DISTANCE COLLAR 3 1 6 x 20 mm SOCKET BOLT 2 4 HOOK DAMPER 5 12 mm WASHER 8 6 mm WASHER 6 LOCK ADJUSTING SPRING 3 COVER LOCK BOLT 7 HOOK BRACKET 9 6 mm HEX NUT ...

Page 123: ...Y 1 Apply grease to the cover lock bolt installation part of the hook bracket 2 Install the lock adjusting spring 12 mm washer and the hook damper on the hook bracket 3 Apply grease to the flanged part of the cover lock bolt Apply grease to the straight part under the flange of the cover lock bolt too Install the cover lock bolt on the hook bracket 4 Position the 6 mm washer and 6 mm hex nut on th...

Page 124: ...e 5 To adjust remove the engine cover and set a wrench or equivalent tool in the cutout in the tapered part of the cover lock bolt Loosen the 6 mm hex nut of the hook bracket assembly 6 After assembly loosely tighten the 6 mm hex nut 7 Install the engine cover on the outboard motor and lock it securely Measure the clearance between the engine cover and the L R engine under covers again If the clea...

Page 125: ...Clean the engine cover and engine cover air guide mating surfaces 2 Apply the sealant Shin Etsu Chemical KE45 or equivalent to the indicated position of the engine cover air guide 3 Tighten the engine cover air guide with the eight 4 x 10 mm self tapping screws securely 4 Install the hook bracket assembly P 4 4 1 Apply the sealant Shin Etsu Chemical KE45 or equivalent ...

Page 126: ...ning the recess at the rear of the front separate cover i e R engine under cover side with the projection of the R engine under cover 2 Install by aligning the projection at the front i e under cover front bracket side of the front separate cover with the recess of the under cover front bracket 1 Rear side 6 Front side 3 FRONT SEPARATE COVER 2 RECESS 4 R ENGINE UNDER COVER 1 FRONT SEPARATE COVER 4...

Page 127: ...cial bolt Check that the special bolt is not on the case but it is tightened properly 4 Tighten the 6 x 25 mm screws and the 6 x 17 mm special bolt securely in the numbered sequence shown in two or three steps 5 Install the undercase grommet band on the remote control cable grommet and fasten the band securely Install the engine cover P 4 2 ...

Page 128: ...e power tilt switch 3P connector from the connector bracket B 3 Disconnect the power tilt switch 3P connector 4 Set a screwdriver in the slot in each mud guard clip as shown and raise the mud guard clips Remove the six mud guard clips 5 Remove the under cover grommet 1 FLUSH PLUG CAP 5 UNDER COVER GROMMET 4 MUD GUARD CLIP 6 3 MUD GUARD CLIP 1 SCREWDRIVER 2 SLOT 2 POWER TILT SWITCH 3P CONNECTOR 1 C...

Page 129: ... x 17 mm special bolts from the L R engine under covers 8 Detach the L engine under cover from the projection of the L side cover bracket 2 5 x 10 mm RIVET SCREW 2 1 14 mm CLIP 2 3 6 x 17 mm SPECIAL BOLT 11 4 6 x 25 mm SCREWS 2 R ENGINE UNDER COVER 1 L ENGINE UNDER COVER 2 PROJECTION 3 L SIDE COVER BRACKET 1 L ENGINE UNDER COVER ...

Page 130: ...acket 9 Open the L engine under cover and disconnect the 7 x 400 mm tube from the water check grommet 11 Remove the L R engine under covers 1 L ENGINE UNDER COVER 1 PROJECTION 3 R SIDE COVER BRACKET 2 R ENGINE UNDER COVER 2 R ENGINE UNDER COVER 1 WATER CHECK GROMMET 2 7 x 400 mm TUBE ...

Page 131: ...TCH Check for continuity between the terminals with the switch in each position 4 POWER TILT SWITCH 3 R ENGINE UNDER COVER 6 POWER TILT SWITCH STAY 5 POWER TILT SWITCH STAY GROMMET 2 WATER JOINT CAP 1 16 mm HEX NUT Continuity Lb W Bl Lg UP Up DN Down 1 UP Up 2 DN Down ...

Page 132: ... x 17 mm SPECIAL BOLT 11 2 L ENGINE UNDER COVER 9 R ENGINE UNDER COVER 8 DRAIN PLUG COVER 13 WATER CHECK GROMMET 4 7 x 400 mm TUBE 11 UNDER COVER GROMMET 12 MUD GUARD CLIP 6 6 FLUSH PLUG CAP 5 POWER TILT SWITCH 3P CONNECTOR 1 6 x 25 mm SCREWS 4 5 N m 0 45 kgf m 3 3 lbf ft ...

Page 133: ...power tilt switch stay with the locking lugs of the power tilt switch f INSTALLATION 1 If the water check grommet is not mounted on the L engine under cover install it from the outside of the L engine under cover 2 Connect the 7 x 400 mm tube to the water check grommet 3 Install the L engine under cover aligning the bottom edge of the L engine under cover with the extension case as shown 5 POWER T...

Page 134: ... under cover with the extension case as shown Note that the 8 x 300 mm tube with the flush plug cap is outside the R engine under cover this time 1 R ENGINE UNDER COVER 3 EXTENSION CASE 2 Align 5 Check that the cover lock cable A is set on the L engine under cover as shown 4 COVER LOCK CABLE A 2 PROJECTION 3 L SIDE COVER BRACKET 1 L SIDE COVER BRACKET 1 L ENGINE UNDER COVER 2 L ENGINE UNDER COVER ...

Page 135: ... cover with the recess in the R engine under cover as shown 3 L ENGINE UNDER COVER 9 With the R engine under cover held in alignment with the L engine under cover described in step 7 install the R engine under cover by aligning the hole in the R engine under cover with the projection on the R side cover bracket 1 RECESS 4 PROJECTIONS 1 PROJECTION 4 R SIDE COVER BRACKET 2 R ENGINE UNDER COVER 3 HOL...

Page 136: ...R 1 L ENGINE UNDER COVER 3 RECESS 2 PROJECTIONS 4 6 x 17 mm SPECIAL BOLT 11 3 6 x 25 mm SCREWS 2 R ENGINE UNDER COVER 1 L ENGINE UNDER COVER 12 Loosely tighten the three 6 x 25 mm screws and the eleven 6 x 17 mm special bolts on the L R engine under covers Check that the special bolts are not on the case but they are tightened properly 13 Tighten the three 6 x 25 mm screws to the specified torque ...

Page 137: ...ch 14 mm clip aligns with the end of the taped part of the power tilt motor wire as shown 15 Tighten the two 5 x 10 mm rivet screws securely while pushing the end of the two 14 mm clips against the corresponding projection on the L engine under cover Take care not to let the alignment points described in the previous step come out of alignment 2 5 x 10 mm RIVET SCREW 2 2 5 x 10 mm RIVET SCREW 2 1 ...

Page 138: ...ilt switch 3P connector on the connector bracket B Clamp the alternator fuse cable PGM FI main relay wire and the power tilt switch wire with the wire harness clip 23 Tighten the flush plug cap on the R engine under cover 24 Install the following parts Electric part cover P 3 22 Front separate cover P 4 7 Engine cover P 4 2 1 FLUSH PLUG CAP 4 POWER TILT SWITCH 3P CONNECTOR 3 CONNECTOR BRACKET B 6 ...

Page 139: ... Remove the trim angle sensor 3P connector and the power tilt motor 2P connector from the connector bracket A Disconnect the trim angle sensor 3P connector and the power tilt motor 2P connector 4 Remove the undercase grommet C outside from the under cover front bracket Pull out the tube and wires through the hole in the under cover front bracket 3 CONNECTOR BRACKET A 2 TRIM ANGLE SENSOR 3P CONNECT...

Page 140: ...VER 1 UNDER COVER FRONT BRACKET 3 6 mm E RING 2 8 mm WASHER 8 LOCK FRONT SHAFT DISASSEMBLY 1 Remove the 6 mm E ring and the 8 mm washer from the lock front shaft 2 Remove the lock front shaft from the under cover front bracket Remove the cover lock lever two cover lock bushing As 10 mm washer and the two 10 mm wave washers Check the cover lock bushing A for scores scratches and other damage Replac...

Page 141: ...t bracket Remove the cover lock bushing and the cover lock hook spring from the front lock 8 Remove the bracket cap 3 Remove the 6 mm E ring from the cover open shaft Remove the cover lock bushing B in a manner of bringing it to the lock lever return spring side With the return spring compressed with the bushing B hold the cover open shaft at a slightly inclined angle Remove the cover open shaft w...

Page 142: ...COVER LOCK BUSHING A 3 10 COVER LOCK LEVER 2 UNDER COVER FRONT BRACKET 3 6 mm E RING 3 1 LOCK FRONT SHAFT 15 COVER LOCK BUSHING B 4 8 mm WASHER 3 13 COVER OPEN SHAFT 8 COVER LOCK BUSHING 7 FRONT LOCK 9 COVER LOCK HOOK SPRING 6 BRACKET CAP 14 LOCK LEVER RETURN SPRING ...

Page 143: ...ver lock cable A and B and disconnect the cover lock cable A and B from the side lock 4 SIDE LOCK 2 LOCK NUT 2 LOCK NUT 3 COVER LOCK CABLE B 1 COVER LOCK CABLE A 2 Remove the two 8 x 55 mm flange bolts and remove the L side cover bracket 1 L SIDE COVER BRACKET 8 x 55 2 ...

Page 144: ...ck the two cover lock bushing As for wear and damage that are mounted on the side lock installation parts on the L side cover bracket Check the cover lock bushing A for scores scratches and other damage Replace the cover lock bushing A with a new one if necessary COMPONENTS DRAWING 5 COVER LOCK BUSHING A 2 8 x 55 2 2 6 mm E RING 1 8 mm WASHER 7 SIDE LOCK 3 COVER LOCK CABLE B 8 COVER LOCK CABLE A 9...

Page 145: ...and remove the R side cover bracket 2 SIDE LOCK 1 LOCK NUT 3 COVER LOCK CABLE B 1 R SIDE COVER BRACKET 6 x 22 2 c R SIDE COVER BRACKET REMOVAL 1 Loosen the lock nut on the cover lock cable B and disconnect the cover lock cable B from the side lock ...

Page 146: ...k hook spring from the hole in the R side cover bracket Remove the side lock from the R side cover bracket Remove the cover lock hook spring from the side lock 3 Remove the two cover lock bushing As from the R side cover bracket Check the cover lock bushing A for scores scratches and other damage Replace the cover lock bushing A with a new one if necessary COMPONENTS DRAWING 1 6 mm E RING 2 8 mm W...

Page 147: ... L SIDE COVER BRACKET 1 Apply marine grease to the cover lock bushing As and install them on the L side cover bracket 2 Apply marine grease to the side lock shaft 3 Install the cover lock hook spring on the side lock aligning the hook of the spring with the hole in the side lock Install the cover lock hook spring on the L side cover bracket aligning another hook of the spring with the hole in the ...

Page 148: ...e 6 mm E ring on the front lock 8 Apply marine grease to the outer surface of the cover open shaft lock lever return spring 8 mm washer and the cover lock bushing B Install the lock lever return spring 8 mm washer and the cover lock bushing B on the cover open shaft Hold the lock lever return spring compressed with the cover lock bushing B 9 Install the cover open shaft at an inclined angle in the...

Page 149: ...cket 14 Install the lock front shaft Install the 8 mm washer and the 6 mm E ring on the lock front shaft e R SIDE COVER BRACKET L SIDE COVER BRACKET UNDER COVER FRONT BRACKET INSTALLATION 1 Install the R side cover bracket with the two 6 x 22 mm flange bolts 2 Install the L side cover bracket with the two 6 x 55 mm flange bolts 1 R SIDE COVER BRACKET 6 x 22 2 1 L SIDE COVER BRACKET 8 x 55 2 8 10 m...

Page 150: ...r and the power tilt motor 2P connector Install the power tilt motor 2P connector on the lower side of the connector bracket A and the trim angle sensor 3P connector on the upper side of the connector bracket A 3 CONNECTOR BRACKET A 1 TRIM ANGLE SENSOR 3P CONNECTOR 2 POWER TILT MOTOR 2P CONNECTOR 1 UNDER COVER FRONT BRACKET 4 HOLE 5 UNDERCASE GROMMET C 2 WIRES 3 TUBE 1 UNDER COVER FRONT BRACKET 2 ...

Page 151: ...e nut in the position described in step 7 position the inner cable end of the cover lock cable A on the front lock and position the cable A nut on the under cover front bracket Tighten the washer side lock nut securely Check that the nut set in step 7 is not out of the position If it is repeat the procedure from step 7 9 Position the 4 x 7 x 160 mm vinyl tube and the 3 5 x 430 mm fuel tube on the ...

Page 152: ...ACKET SIDE 3 LOCK NUT 1 COVER LOCK CABLE A 6 SIDE LOCK 13 Adjust the length between the end of the cable outer and the end of the nut of the cover lock cable B shorter one so that it is 13 mm 0 5 in as shown 14 Holding the nut in the position described in step 13 position the inner cable end of the cover lock cable B on the side lock and position the cable B nut on the L side cover bracket Tighten...

Page 153: ...6 Adjust the length between the other end of the cable outer and the end of the nut of the cover lock cable B so that it is 13 mm 0 5 in as shown 17 Holding the nut in the position described in step 16 position the inner cable end of the cover lock cable B on the side lock and position the cable B nut on the R side cover bracket Tighten the washer side lock nut securely Check that the nut set in s...

Page 154: ...ANIFOLD 13 FUEL INJECTOR PRESSURE REGULATOR 14 FUEL PUMP LOW PRESSURE SIDE 15 FUEL STRAINER LOW PRESSURE SIDE WATER SEPARATOR 16 EOP ENGINE OIL PRESSURE SWITCH HIGH PRESSURE SIDE 17 EOP ENGINE OIL PRESSURE SWITCH LOW PRESSURE SIDE 18 ECT ENGINE COOLANT TEMPERATURE SENSOR 1 19 ECT ENGINE COOLANT TEMPERATURE SENSOR 2 3 4 20 BARO BAROMETRIC PRESSURE SENSOR 21 KNOCK SENSOR 22 CMP CAMSHAFT POSITION SEN...

Page 155: ... the battery cable to the battery negative ter minal FUEL LEAK CHECK Turn the ignition switch ON but do not turn the starter after connecting the fuel lines The fuel pump unit high pressure side should operate for approximately 2 sec onds and the fuel pressure in the high pressure side fuel line should rise Repeat this operation 2 or 3 times and check for fuel leakage WHEN THE BOAT IS EQUIPPED WIT...

Page 156: ...RE SIDE ECT ENGINE COOLANT TEMPERATURE SENSOR 4 ECT ENGINE COOLANT TEMPERATURE SENSOR 3 ECT ENGINE COOLANT TEMPERATURE SENSOR 2 IAT INTAKE AIR TEMPERATURE SENSOR ECT ENGINE COOLANT TEMPERATURE SENSOR 1 TP THROTTLE POSITION SENSOR BARO BAROMETRIC PRESSURE SENSOR MAP MANIFOLD ABSOLUTE PRESSURE SENSOR CKP CRANKSHAFT POSITION SENSOR CMP CAMSHAFT POSITION SENSOR FUEL PUMP HIGH PRESSURE SIDE To STARTER ...

Page 157: ...UZZER MIL ACG INDICATOR LIGHT IC REGULATOR ALTERNATOR INDICATOR LIGHT OVERHEAT INDICATOR LIGHT OIL INDICATOR LIGHT TACHOMETER PULSE CHECK CONNECTOR TACHOMETER OPTION DATA LINK CONNECTOR EMERGENCY STOP SWITCH TRIM METER OPTION TRIM ANGLE SENSOR EOP ENGINE OIL PRESSURE SWITCH LOW PRESSURE SIDE WATER LEVEL SWITCH NEUTRAL SWITCH ...

Page 158: ... FILTER SILENCER CASE TP THROTTLE POSITION SENSOR MAP MANIFOLD ABSOLUTE PRESSURE SENSOR IAC IDLE AIR CONTROL VALVE VACUUM TANK IAB INTAKE AIR BYPASS CONTROL SOLENOID VALVE DIAPHRAGM INJECTOR WATER SEPARATOR FUEL STRAINER BREATHER CHAMBER FUEL PUMP LOW PRESSURE SIDE PRESSURE REGULATOR To MOUNT CASE A A ...

Page 159: ...ENSOR BARO BAROMETRIC PRESSURE SENSOR ECT ENGINE COOLANTTEMPERATURE SENSOR 2 INJECTOR IAB INTAKE AIR BYPASS CONTROL SOLENOID VALVE KNOCK SENSOR FUEL PUMP HIGH PRESSURE SIDE WATER LEVEL SENSOR TP THROTTLE POSITION SENSOR MAP MANIFOLD ABSOLUTE PRESSURE SENSOR IAC IDLE AIR CONTROL VALVE ...

Page 160: ...CRANKSHAFT POSITION SENSOR ECT ENGINE COOLANT TEMPERATURE SENSOR 1 ECM ENGINE CONTROL MODULE A F AIR FUEL RATIO SENSOR RELAY PGM FI MAIN RELAY EOP ENGINE OIL PRESSURE SWITCH HIGH PRESSURE SIDE EOP ENGINE OIL PRESSURE SWITCH LOW PRESSURE SIDE CMP CAMSHAFT POSITION SENSOR ECT ENGINE COOLANT TEMPERATURE SENSOR 3 ...

Page 161: ...2 Fuel pump relay 2 14 Bl Y AFC1 A F sensor C 15 R Bu KS Knock sensor 16 R TOH2 ECT sensor 3 Detects exhaust port temperature 17 Y R OPSH EOP switch High pressure side At switch ON Approx 0V At switch OFF Battery voltage 18 Not used 19 Br EFD Fuel filter water level switch At switch ON High water level Approx 0V At switch OFF Battery voltage 20 G Y VTS VTEC solenoid valve Power to drive solenoid v...

Page 162: ...l At ignition switch ON Approx 12V 16 Lg W SCS Service check signal 17 G Bl LG1 Logic ground 1 18 Y G BUZZ Buzzer Power to sound buzzer 19 W Bu ACGL Alternator indicator light Inputs alternator indicator light ON signal 20 Bl R EMS1 Emergency stop switch 1 At switch ON Approx 0V At switch OFF Battery voltage 21 Br INJ1 No 1 injector Power to drive No 1 injector 22 Bu IGN1 No 1 ignition coil Output...

Page 163: ...nt Signal No color mark 1 Y Bl IGP1 ECM main power 1 Common with C5 At ignition switch ON Battery voltage 2 G PG1 Power ground 1 Common with C6 3 Bl W AFHT A F sensor heater 4 W AFHT A F sensor heater 5 Y Bl IGP2 ECM main power 2 Common with C1 At ignition switch ON Battery voltage 6 G R PG2 Power ground 2 Common with C2 ...

Page 164: ...oot connect the tester probe to a commer cially available digital circuit tester Note that the tester probe must agree with the connector terminal of the digi tal circuit tester not to apply excessive force to the con nector terminal 1 Turn the ignition switch ON and check that the MIL comes ON 2 When the MIL is ON or blinking check the DTC Diagnostic Trouble Code using the HDS tester P 5 13 Or us...

Page 165: ... Check point Idle IAC Neutral Vacuum adjusting screw valve switch pipe Symptom Ref page 5 94 5 95 17 13 5 5 Engine does not start 2 1 Engine starts but stalls soon 1 2 3 Engine speed is higher than the specified idle speed 3 2 1 after warm up Engine speed is higher than the specified trolling speed 3 4 1 2 after warm up Engine speed is lower than the specified idle speed 2 1 3 after warm up Engine...

Page 166: ...G CRUISING 1 Remove the engine cover and the electric part cover Section 4 2 Remove the cap from the under cover front bracket Route the extension wire in the HDS pocket tester kit through the front cover bracket Set the grommet on the under cover front bracket securely 3 Disconnect the red 4P connector from the DLC Data Link Connector and secure the DLC wire as sown Route the extension wire of th...

Page 167: ...ctor DLC 3 Turn the ignition switch ON 4 Clear the DTC using the HDS pocket tester Refer to the HDS pocket tester s operation manual for how to use the HDS pocket tester When abnormality remains in the system the DTC cannot be cleared as the ECM continues self diag nosis FINAL PROCEDURE AFTER TROUBLESHOOTING 1 Clear the DTC 2 Disconnect the HDS pocket tester wire from the data link connector 3 Ins...

Page 168: ... Faulty MAP sensor Faulty ECM 4 1 MIL stays ON CKP sensor No pulse Open short circuit in CKP sensor wire 5 30 CKP sensor Faulty ECM 4 2 MIL stays ON CKP sensor Abnormal pulse Faulty CKP sensor 5 32 Faulty ECM 6 1 MIL stays ON ECT sensor 1 Voltage too low Short circuit in ECT sensor 1 5 33 Faulty ECT sensor 1 Faulty ECM 6 2 MIL stays ON ECT sensor 1 Voltage too high Open circuit in ECT sensor 1 wir...

Page 169: ...cuit in VTEC solenoid valve 5 42 Abnormal output BF150A only Faulty VTEC solenoid valve Faulty ECM 23 1 MIL comes ON Knock sensor Abnormal detection Open short circuit in knock sensor wire 5 43 Faulty knock sensor Faulty ECM 41 3 MIL comes ON A F sensor heater Open short circuit in A F sensor heater wire 5 44 Abnormal current flow Faulty A F sensor heater Faulty ECM 41 4 MIL comes ON A F sensor he...

Page 170: ...y ECM 141 2 MIL comes ON ECT sensor 3 Voltage too high Open circuit in ECT sensor 3 wire 5 53 Faulty ECT sensor 3 Faulty ECM 142 1 MIL comes ON EOP switch Open short circuit in EOP switch wire 5 54 Abnormal signal Faulty ECM 143 1 MIL comes ON ECT sensor 4 Voltage too low Short circuit in ECT sensor 4 wire 5 55 Faulty ECT sensor 3 Faulty ECM 143 2 MIL comes ON ECT sensor 4 Voltage too high Open ci...

Page 171: ... and between the fuse box and the power trim tilt switch or power tilt switch After repair replace the No 3 fuse 2 Main power line check 1 Disconnect the remote control harness 14P connector 2 Measure the voltage between the No 3 White Black terminal of the main harness side 14P connector and the engine ground Note that voltage is constantly applied to the White Black terminal Take care not to sho...

Page 172: ...ween the No 3 Yellow Black terminal of the fuse box side 3P connector and the engine ground Is there the battery voltage YES Go to the step 3 NO The PGM FI main relay is faulty or the fuse box is faulty 3 Turn the ignition switch OFF and disconnect the ECM connector C 4 Check for the continuity between the No 2 Yellow Black terminal of the fuse box harness side 3P con nector and the respective ter...

Page 173: ... BF135A BF150A 5 MIL power line check 1 Turn the ignition switch OFF and disconnect the fuse box 3P connector 2 Turn the ignition switch ON Measure the voltage between the No 2 Yellow Red terminal of the fuse box side 3P connector and the engine ground Is there the battery voltage YES Go to the step 3 NO The PGM FI main relay is faulty 3 Turn the ignition switch OFF and connect the fuse box 3P con...

Page 174: ...urn the ignition switch ON Measure the voltage between the respective terminals of the No 2 Yellow Black and No 6 Yellow Black terminals of the ECM connector C and the engine ground Is there the battery voltage YES Perform 2 Data link connector check NO Repair open in the main harness 2 Data link connector check 1 Turn the ignition switch OFF and disconnect the HDS pocket tester 2 Turn the ignitio...

Page 175: ...ir open in the main harness 6 Check for the continuity between the service check connector No 1 Black terminal and the engine ground Is there the continuity YES Perform 3 DTC recheck NO Repair open in the main harness 3 DTC recheck 1 Turn the ignition switch OFF and connect the HDS pocket tester 2 Turn the ignition switch ON and check the DTC with the HDS pocket tester Is the main code 0 either of...

Page 176: ...sconnect the Yellow Green terminal from the buzzer 2 Connect theYellow Green terminal of the buzzer to the Black terminal with a jumper wire to short 3 Turn the ignition switch ON and check that the buzzer sounds Does the buzzer sound YES Repair open in the wire harness wire between the buzzer and ECM NO Go to the step 4 4 Perform the unit check of the buzzer Is the buzzer normal YES Go to the ste...

Page 177: ...onnector and the engine ground Is there the battery voltage YES Go to the step 3 NO Repair open in the main wire harness 3 Turn the ignition switch OFF and disconnect the ECM connector B 4 Check for the continuity between the No 25 Red Blue terminal of the ECM harness side connector B and the No 4 Red Blue terminal of the MIL main harness side 6P connector Is there the continuity YES Go to the ste...

Page 178: ...e control harness 5 Oil pressure indicator line check 1 Turn the ignition switch OFF Disconnect theYellow ter minal of the indicator light and connect the Black ter minal to short 2 Turn the ignition switch ON and check the oil pressure indicator light Does the oil pressure indicator light come ON YES Go to the step 3 NO Repair open in the wire harness between the ECM and the indicator light 3 Tur...

Page 179: ...r and the engine ground Is there the continuity YES Go to the step 4 NO Repair open in the main wire harness 4 Disconnect the ECM connector B 5 Check for the continuity between the No 13 Black Blue terminal of the ECM harness side con nector B and the No 1 Black Blue terminal of the neutral switch harness side 2P connector Is there the continuity YES Perform 3 Neutral switch check NO Repair open i...

Page 180: ...Perform 3 Tachometer pulse line check NO Repair open in the wire of the meter harness 3 Tachometer pulse line check 1 Turn the ignition switch OFF and disconnect the ECM connector B 2 Disconnect the remote control harness 14P connector 3 Check for the continuity between the No 12 Gray ter minal of the main harness side 14P connector and the engine ground Is there the continuity YES Repair short in...

Page 181: ...tester Is the measured voltage 0 22 to 3 15V YES Temporary failure Disappeared NO Perform 2 MAP sensor signal line short cir cuit test 2 MAP sensor signal line short circuit test 1 Turn the ignition switch OFF and disconnect the MAP sensor 3P connector 2 Disconnect the ECM connector A 3 Check for the continuity between the No 2 White Red terminal of the MAP sensor harness side 3P connec tor and th...

Page 182: ...low termi nal of the ECM harness side connector B Is there the continuity YES Perform 4 MAP sensor ground line open cir cuit check NO Repair open in the wire between the MAP sensor and the ECM 4 MAP sensor ground line open circuit check 1 Check for the continuity between the No 1 Green Red terminal of the MAP sensor harness side 3P connector and the body ground Is there the continuity YES Perform ...

Page 183: ...oduction test 1 Connect the HDS pocket tester and clear the DTC once If the DTC can not be cleared go on the trou bleshooting 2 Start the engine and let it run at idling under no load 3 Check the DTC using the HDS pocket tester Does the DTC 4 1 appear YES Perform 2 CKP sensor power line check NO Temporary failure Disappeared 2 CKP sensor power line check 1 Turn the ignition switch OFF and disconne...

Page 184: ...rt circuit check 1 Turn the ignition switch OFF Check for continuity between the No 3 Blue terminal of the CKP sensor harness side 3P connector and the engine ground Is there the continuity YES Perform 6 CKP sensor ground line short cir cuit check NO Repair open in the wire between the CKP sensor and the ECM 6 CKP sensor ground line open circuit check 1 Turn the ignition switch OFF Check for conti...

Page 185: ...P pulse is abnormal 1 Symptom reproduction test 1 Connect the HDS pocket tester and clear the DTC once If the DTC can not be cleared go on the trou bleshooting 2 Start the engine and let it run at idling under no load 3 Check the DTC with the HDS pocket tester Does the DTC 4 2 appear YES Check the crank pulse plate for deformation and damage Replace the crank pulse plate with a new one if it is de...

Page 186: ... ECM and recheck NO Replace the ECT sensor 1 and recheck DTC 6 2 ECT sensor 1 voltage is high 1 Symptom reproduction test 1 Connect the HDS pocket tester and clear the DTC once If the DTC can not be cleared go on the trou bleshooting 2 Turn the ignition switch ON 3 Measure the ECT sensor 1 voltage using the HDS pocket tester Is the measurement 0 23 3 15V YES Temporary failure Disappeared NO Go to ...

Page 187: ...pocket tester Is the measurement 0 08 4 92V YES Temporary failure Disappeared NO Perform 2 TP sensor signal line short circuit check 2 TP sensor signal line short circuit check 1 Turn the ignition switch OFF and disconnect the TP sensor connector 2 Disconnect the ECM connector B 3 Check for continuity between the No 2 Red Black ter minal of the TP sensor harness side 3P connector and the engine gr...

Page 188: ...or power line open circuit check 3 TP sensor power line open circuit check 1 Turn the ignition switch ON Measure the voltage between the No 3 Brown White terminal of the TP sensor harness side 3P connector and the engine ground Is the measurement 4 75 5 25V YES Repair open in the wire between the TP sen sor and the engine ground NO Repair open in the wire between the TP sen sor and the ECM 4 TP se...

Page 189: ...at idling under no load 3 Check the DTC using the HDS pocket tester Does the DTC 8 1 appear YES Check the pulse plate If it is normal perform 2 CMP sensor power line check If it is abnormal replace the pulse plate and recheck NO Temporary failure Disappeared 2 CMP sensor power line check 1 Turn the ignition switch OFF and disconnect the CMP sensor 3P connector 2 Turn the ignition switch ON Measure...

Page 190: ...nnect the HDS pocket tester and clear the DTC once 2 Start the engine and let it run at idling under no load Check the DTC using the HDS pocket tester Does the DTC 8 1 appear YES Replace the CMP sensor and recheck If the DTC 8 1 appears again substitute a known good ECM and recheck NO End of the check DTC 8 2 CMP sensor pulse is abnormal 1 Symptom reproduction test 1 Connect the HDS pocket tester ...

Page 191: ...r with a new one and recheck DTC 10 2 IAT sensor voltage is high 1 Symptom reproduction test 1 Connect the HDS pocket tester and clear the DTC once If the DTC can not be cleared go on the trou bleshooting 2 Turn the ignition switch ON 3 Measure the IAT sensor TA voltage using the HDS pocket tester Is the measured voltage 0 08 4 92V YES Temporary failure Disappeared NO Perform 2 IAT sensor signal l...

Page 192: ...r PA voltage using the HDS pocket tester Is the measurement voltage 1 58 4 49V YES Temporary failure Disappeared NO Perform 2 BARO sensor signal line short cir cuit check 2 BARO sensor signal line short circuit check 1 Turn the ignition switch OFF and disconnect the ECM connector B 2 Check for the continuity between the No 2 White Blue terminal of the BARO sensor harness side 3P connector and the ...

Page 193: ... terminal of the BARO sensor harness side 3P connector and the engine ground Is the measured voltage 4 75 5 25V YES Repair open in the wire between the BARO sensor and the engine ground NO Repair open in the wire between the BARO sensor and the ECM 4 BARO sensor signal line open circuit check 1 Turn the ignition switch ON Measure the voltage between the No 2 White Blue terminal of the BARO sensor ...

Page 194: ...rt circuit check 1 Check for the continuity between the IAC valve No 1 terminal and the body ground Is there the continuity YES Replace the IAC valve NO Go to the step 2 2 Check for the continuity between the IAC valve No 2 terminal and the body ground Is there the continuity YES Replace the IAC valve NO Perform 4 IAC valve line open circuit check 4 IAC valve line open circuit check 1 Connect the ...

Page 195: ... 5 minutes by run ning the engine at 3 000 min 1 rpm under no load 3 Disconnect the neutral switch 2P connector 4 Increase the engine speed gradually and run the engine at 4 500 min 1 rpm for a few seconds 5 Check the DTC again using the HDS pocket tester Does the DTC 21 1 appear YES Perform 2 Spool solenoid valve check NO Temporary failure Disappeared 2 Spool solenoid valve check 1 Turn the ignit...

Page 196: ...can not be cleared go on the trou bleshooting 2 Start the engine and warm it up for 5 minutes or more by running the engine at 5 000 min 1 rpm or more under no load 3 Check the DTC again with the HDS pocket tester Does the DTC 23 1 appear YES Perform 2 Knock sensor signal line open cir cuit check NO Temporary failure Disappeared 2 Knock sensor signal line open circuit check 1 Turn the ignition swi...

Page 197: ...k NO Temporary failure Disappeared 2 A F heater relay check 1 Turn the ignition switch OFF and disconnect the A F sensor 4P connector 2 Turn the ignition switch ON Measure the voltage between the No 3 White terminal of the A F sensor harness side 4P connector and the engine ground Is there the battery voltage YES Perform 3 A F sensor heater check NO Go to the step 3 3 Turn the ignition switch OFF ...

Page 198: ...the A F heater relay and the ECM 9 Check for the continuity between the No 3 White ter minal of the A F heater relay harness side 4P connec tor and the No 3 White terminal of the A F sensor harness side 4P connector Is there the continuity YES Perform 3 A F sensor heater check NO Repair open in the wire between the A F heater relay and the A F sensor 3 A F sensor heater check 1 Turn the ignition s...

Page 199: ...g 2 Start the engine and warm it up for 5 minutes or more by running the engine at 3 000 min 1 rpm under no load 3 Check the DTC again using the HDS pocket tester Does the DTC 41 4 appear YES Perform 2 A F heater relay check NO Temporary failure Disappeared 2 A F heater relay check 1 Turn the ignition switch OFF and disconnect the A F sensor 4P connector 2 Turn the ignition switch ON Measure the v...

Page 200: ... between the A F heater relay and the ECM 9 Check for the continuity between the No 3 White ter minal of the A F heater relay harness side 4P connec tor and the No 3 White terminal of the A F sensor harness side 4P connector Is there the continuity YES Perform 3 A F heater check NO Repair open in the wire between the A F heater relay and the A F sensor 3 A F heater check 1 Turn the ignition switch...

Page 201: ...nector C and the engine ground and between the No 4 White ter minal of the ECM connector C and the engine ground Is there the continuity YES Repair short in the wire between the A F sen sor and the ECM NO Perform 5 Heater line open circuit check 5 Heater line open circuit check 1 Turn the ignition switch OFF and connect the A F sen sor 4P connector 2 Measure the resistance between the No 3 Black W...

Page 202: ...ck for the continuity between the No 1 White Black terminal of the A F sensor harness side 4P connector and the No 4 White Black terminal of the ECM connector A Is there the continuity YES Go to the step 3 NO Repair open in the wire between the A F sen sor and the ECM 3 Check for the continuity between the No 2 Black Yellow terminal of the A F sensor harness side 4P connector and the No 14 Black Y...

Page 203: ...a known good ECM and recheck DTC 48 7 A F sensor C current is abnormal 1 Symptom reproduction test 1 Connect the HDS pocket tester and clear the DTC once If the DTC can not be cleared go on the trou bleshooting 2 Start the engine and warm it up for 5 minutes or more by running the engine at 3 000 min 1 rpm under no load 3 Check the DTC again using the HDS pocket tester Does the DTC 48 7 appear YES...

Page 204: ...r 2 temperature using the HDS pocket tester Does the measurement correspond to the engine coolant temperature YES Substitute a known good ECM and recheck NO Replace the ECT sensor 2 DTC 140 2 ECT sensor 2 voltage is high 1 Symptom reproduction test 1 Connect the HDS pocket tester and clear the DTC once If the DTC can not be cleared go on the trou bleshooting 2 Turn the ignition switch ON 3 Measure...

Page 205: ...he ignition switch ON 3 Measure the ECT sensor 3 voltage using the HDS pocket tester Is the measured voltage 0 08 4 99V YES Temporary failure Disappeared NO Perform 2 ECT sensor 3 signal line short cir cuit check 2 ECT sensor 3 signal line short circuit check 1 Turn the ignition switch OFF Disconnect the ECT sen sor 3 connector and the ECM connector B 2 Check for the continuity between the No 2 te...

Page 206: ...sensor 3 ground line open circuit check NO Repair open in the wire between the ECT sensor 3 and the ECM 3 ECT sensor 3 ground line open circuit check 1 Connect the ECM connector B 2 Check for continuity between the No 1 Green Red terminal of the ECT sensor 3 harness side 2P con nector and the body ground Is there the continuity YES Perform 4 ECT sensor 3 check NO Repair open in the wire between th...

Page 207: ... Repair open in the wire between the EOP switch and the ECM 3 EOP switch signal line short circuit check 1 Turn the ignition switch OFF Disconnect the EOP switch 2P connector and the ECM connector A 2 Check for the continuity between the No 1 Yellow Red terminal of the EOP switch harness side 2P connector and the body ground Is there the continuity YES Repair short in the wire between the EOP swit...

Page 208: ... NO Perform 2 ECT sensor 4 signal line short cir cuit check 2 ECT sensor 4 signal line short circuit check 1 Turn the ignition switch OFF Disconnect the ECT sen sor 4 connector and the ECM connector B 2 Check for the continuity between the No 2 Red Green terminal of the ECT sensor 4 harness side connector and the body ground Is there the continuity YES Repair short in the wire between the ECT sens...

Page 209: ...CT sensor 4 ground line open circuit check NO Repair open in the wire between the ECT sensor 4 and the ECM 3 ECT sensor 4 ground line open circuit check 1 Connect the ECM connector B 2 Check for the continuity between the No 1 Green Red terminal of the ECT sensor 4 harness side 2P connector and the body ground Is there the continuity YES Perform 4 ECT sensor 4 check NO Repair open in the wire betw...

Page 210: ...et Procedure 1 Turn the ignition switch OFF 2 Short circuit the 4P Red data link connector located inside the electric part cover using the special tool SCS short connector 3 Turn the ignition switch ON 4 Turn the emergency stop switch ON push and OFF release Repeat this procedure five times Repeat turning the switch ON for 0 5 sec or more and turning it OFF for 0 1 sec or more 5 Check that the bu...

Page 211: ...leshooting 1 Disconnect the SCS short connector from the data link connector Note that the MIL stays ON while the SCS short con nector is connected to the data link connector 2 Be sure to reset the ECM after troubleshooting The MIL can come ON or blink when the ECM detect ed poor or loose contact of a connector If it is hard to identify the problem part by following the troubleshoot ing flow chart...

Page 212: ...rcuit in ECT sensor 1 wire 5 74 Faulty ECT sensor 1 Faulty ECM 7 ON TP sensor Sensor voltage Open or short circuit in TP sensor wire 5 75 Faulty TP sensor Faulty ECM 8 ON CMP sensor Pulse Open or short circuit in CMP sensor 5 77 Faulty CMP sensor Faulty ECM 10 ON IAT sensor Sensor voltage Open or short circuit in IAT sensor wire 5 78 Faulty IAT sensor Faulty ECM 13 ON BARO sensor Sensor voltage Sh...

Page 213: ... EOP switch wire 5 87 Faulty ECM 27 ON ECT sensor 4 Open or short circuit in the ECT sensor 4 wire 5 89 Sensor voltage Faulty ECT sensor 4 Faulty ECM 41 ON A F sensor heater Current Open or short circuit in the A F sensor 5 90 heater wire Faulty A F sensor heater Faulty ECM 48 ON A F sensor Current Open or short circuit in the A F sensor wire 5 92 Faulty A F sensor Faulty ECM MIL Detected unit Pro...

Page 214: ... box and power trim tilt switch or the power tilt switch After repair replace the No 3 fuse 2 Main power supply line check 1 Disconnect the remote control harness 14P connector 2 Measure the voltage between the No 3 White Black terminal of the main harness side 14P connector and the engine ground Note that the battery voltage is constantly applied to the White Black terminal Take care not to short...

Page 215: ...nition switch ON Measure the voltage between the No 3 Yellow Black terminal of the fuse box side 3P connector and the engine ground Is there the battery voltage YES Go to the step 3 NO PGM FI main relay is faulty or fuse box is faulty 3 Turn the ignition switch OFF and disconnect the ECM connector C 4 Check for the continuity between the No 2 Yellow Black terminal of the fuse box harness side 3P c...

Page 216: ... there the battery voltage YES Perform 6 Alternator indicator light check NO Repair open in the main wire harness 6 Alternator indicator light check 1 Turn the ignition switch ON and check the alternator indicator light Does the alternator indicator light come ON YES Perform 7 MIL ON line check NO Replace the MIL 7 MIL ON line check 1 Turn the ignition switch OFF and connect the test har ness 2 Co...

Page 217: ... between the ECM and the data link connector NO Go to the step 6 6 Connect the SCS short connector to the data link con nector to short circuit 7 Measure the voltage between the test harness B 16 terminal and A 1 terminal and between the B 16 terminal and B 17 terminal Is the measured voltage 4 30 5 25V YES Go to the step 8 NO Go to the step 10 8 Disconnect the SCS short connector 9 Turn the ignit...

Page 218: ...ground with the ECM connec tor A disconnected Is there the continuity YES Repair open in the main harness between the ECM and the MAP sensor NO Go to the step 9 9 With the ECU connector A disconnected check for the continuity between the test harness A 12 terminal and the engine ground Is there the continuity YES Repair open in the wire between the ECM and the BARO sensor NO Perform 4 ECM main pow...

Page 219: ...ition switch ON and check that the buzzer sounds Does the buzzer sound YES Perform 3 Overheat indicator line check NO Go to the step 3 3 Turn the ignition switch OFF and disconnect the Yellow Green terminal from the buzzer 4 Connect theYellow Green terminal of the buzzer to the Black terminal with a jumper wire to short circuit 5 Turn the ignition switch ON and check whether the buzzer sounds Does...

Page 220: ... control harness 4 Oil pressure indicator line check 1 Connect the test harness B 32 terminal to the engine ground to short circuit 2 Turn the ignition switch ON and check the oil pressure indicator light Does the oil pressure indicator light come ON YES Go to the step 3 NO Perform 5 MIL line check 3 Turn the ignition switch OFF Disconnect the indicator light Yellow terminal and connect it to the ...

Page 221: ...ternator indicator line check 1 Turn the ignition switch OFF and disconnect the alter nator 4P connector 2 Check for the continuity between the test harness B 19 terminal and the engine ground Is there the continuity YES Repair short in the wire between the ECM and the alternator NO Go to the step 3 3 Check for the continuity between the No 1 White Blue terminal of the alternator harness side 4P c...

Page 222: ...side line check NO Repair open in the main harness between the low pressure side EOP switch and the ECM 9 EOP switch high pressure side line check 1 Disconnect the high pressure side EOP switch 2P con nector 2 Check for the continuity between the test harness A 17 terminal and the engine ground Is there the continuity YES Repair short in the main harness between the high pressure side EOP switch a...

Page 223: ...wn good ECM and recheck Tachometer Malfunction Tachometer does not function so that it corre sponds to the engine speed 1 Tachometer power supply check 1 Turn the ignition switch OFF and disconnect the tachometer s connecting terminal 2 Turn the ignition switch ON and measure the voltage between the harness side Black Yellow terminal and the Black terminal Is there the battery voltage YES Perform ...

Page 224: ... NO Repair open in the wire between the ECM and the MAP sensor 3 MAP sensor signal line open circuit check 1 Connect the ECM connector A 2 Turn the ignition switch ON 3 Measure the voltage between the No 2 White Red terminal of the MAP sensor harness side 3P connec tor and the engine ground Is the measurement 4 75 5 25V YES Perform 4 MAP sensor signal line short cir cuit check NO Repair open in th...

Page 225: ...YES Perform 2 CKP sensor power supply line open circuit check NO Temporary failure Disappeared 2 CKP sensor power supply line open circuit check 1 Turn the ignition switch OFF and disconnect the CKP sensor 3P connector 2 Turn the ignition switch ON and measure the voltage between the No 1 Yellow Black terminal of the CKP sensor harness side 3P connector and the engine ground Is there the battery v...

Page 226: ...he ECM 5 CKP sensor ground line open circuit check 1 Check for the continuity between the No 2 Green Black terminal of the CKP sensor harness side 3P connector and the engine ground Is there the continuity YES Perform 6 CKP sensor check NO Repair open in the wire between the CKP sensor and the ECM 6 CKP sensor check 1 Reset the ECM 2 Start the engine and let it run at idling under no load Check th...

Page 227: ...d ECT sensor 1 3 ECT sensor 1 line short circuit check 1 Turn the ignition switch OFF and disconnect the ECM connector B 2 Check for the continuity between the No 2 Red White terminal of the ECT sensor 1 harness side 2P con nector and the body ground Is there the continuity YES Repair short in the wire between the ECM and the ECT sensor 1 NO Perform 4 ECT sensor 1 ground line short circuit check 4...

Page 228: ...ion switch ON 4 Measure the voltage between the B 7 terminal and the A 2 terminal of the test harness Is the measured voltage 0 08 4 92V YES Temporary failure Disappeared NO Perform 2 TP sensor power supply line open circuit check 2 TP sensor power supply line open circuit check 1 Turn the ignition switch ON Measure the voltage between the No 3 Brown White terminal of the TP sensor harness side 3P...

Page 229: ...rcuit check 5 TP sensor ground line open circuit check 1 Turn the ignition switch OFF and disconnect the TP sensor 3P connector 2 Check for the continuity between the No 1 Green Red terminal of the TP sensor harness side 3P con nector and the engine ground Is there the continuity YES Perform 6 TP sensor check NO Repair open in the wire between the TP sen sor and the engine ground 6 TP sensor check...

Page 230: ...sensor signal line short cir cuit check NO Repair open in the wire between the CMP sensor and the ECM 4 CMP sensor signal line short circuit check 1 Turn the ignition switch OFF and disconnect the CMP sensor 3P connector 2 Check for the continuity between the No 3 Green ter minal of the CMP sensor harness side 3P connector and the engine ground Is there the continuity YES Repair short in the wire ...

Page 231: ... the voltage between the B 11 terminal and the A 2 terminal of the test harness Is the voltage 0 08 4 92V YES Temporary failure Disappeared NO Perform 2 IAT sensor signal line open circuit check 2 IAT sensor signal line open circuit check 1 Turn the ignition switch OFF and disconnect the IAT sensor 2P connector 2 Turn the ignition switch ON Measure the voltage between the No 2 Red Yellow terminal ...

Page 232: ...ess side 2P con nector and the body ground Is there the continuity YES Perform 5 IAT sensor check NO Repair open in the wire between the IAT sen sor and the engine ground 5 IAT sensor check 1 Turn the ignition switch OFF and disconnect the IAT sensor 2P connector 2 Measure the resistance between the No 1 and the No 2 terminals of the IAT sensor side 2P connector Is there the resistance correspondi...

Page 233: ...wire between the BARO sensor and the ECM 3 BARO sensor signal line open circuit check 1 Turn the ignition switch ON Measure the voltage between the No 2 White Blue terminal of the BARO sensor harness side 3P connector and the body ground Is the voltage 4 75 5 25V YES Perform 4 BARO sensor signal line short cir cuit check NO Repair open in the wire between the BARO sensor and the ECM 4 BARO sensor ...

Page 234: ... switch OFF and connect the test har ness Hold the sensor connector connected 3 Start the engine Check the engine speed during idling Is the engine speed 650 rpm or above YES Temporary failure Disappeared NO Perform 2 IAC valve open circuit check 2 IAC valve open circuit check 1 Turn the ignition switch OFF and disconnect the IAC valve 2P connector 2 Measure the resistance between the IAC valve No...

Page 235: ...e IAC valve NO Substitute a known good ECM and recheck VTEC Solenoid Valve Troubleshooting MIL blinks 21 times 1 Spool solenoid valve check 1 Turn the ignition switch OFF and disconnect the spool solenoid valve connector 2 Measure the resistance between the spool solenoid valve side 1P connector terminal Green White and the body ground Is the measured resistance 12 18 YES Perform 2 VTEC signal lin...

Page 236: ...y substitute a known good ECM and recheck KNOCK Sensor Troubleshooting MIL blinks 23 times 1 Symptom reproduction test 1 Reset the ECM 2 Turn the ignition switch OFF and connect the test har ness Hold the sensor connector connected 3 Start the engine and let it warm up by running the engine at 5 000 min 1 rpm or more for 5 minutes or more under no load 4 Check the MIL Does the MIL come ON YES Perf...

Page 237: ...re the voltage between the test harness B 12 terminal and the A 2 terminal Is the voltage 0 08 4 99V YES Temporary failure Disappeared NO Perform 2 ECT sensor 2 signal line open cir cuit check 2 ECT sensor 2 signal line open circuit check 1 Turn the ignition switch OFF Disconnect the 2P con nector from the ECT sensor 2 2 Turn the ignition switch ON 3 Measure the voltage between the No 2 Red Black ...

Page 238: ...sor 2 harness side 2P connector and the body ground Is there the continuity YES Perform 5 ECT sensor 2 check NO Repair open in the wire between the ECT sensor 2 and the engine ground 5 ECT sensor 2 check 1 Turn the ignition switch OFF and disconnect the 2P connector of the ECT sensor 2 2 Measure the resistance between the No 1 and the No 2 terminals of the ECT sensor 2 side 2P connector Is there t...

Page 239: ...sor 3 and the ECM 3 ECT sensor 3 signal line short circuit check 1 Turn the ignition switch OFF Disconnect the ECT sen sor 3 connector and the ECM connector B 2 Check for the continuity between the No 2 Red ter minal of the ECT sensor 3 harness side 2P connector and the body ground Is there the continuity YES Repair short in the wire between the ECT sensor 3 and the engine ground NO Perform 4 ECT ...

Page 240: ...tage between the test harness A 17 terminal and A 2 terminal Is the voltage 0V OFF signal YES Temporary failure Disappeared NO Perform 2 EOP switch signal line open cir cuit check 2 EOP switch signal line open circuit check 1 Turn the ignition switch OFF and disconnect the EOP switch 2P connector 2 Turn the ignition switch ON Measure the voltage between the No 1 Yellow Red terminal of the EOP swit...

Page 241: ...o 2 Green Red terminal of the EOP switch harness side 2P con nector and the body ground Is there the continuity YES Perform 5 EOP switch check NO Repair open in the wire between the EOP switch and the ECM 5 EOP switch check 1 Turn the ignition switch OFF and connect each con nector 2 Turn the ignition switch ON and measure the voltage between the test harness A 17 terminal and the A 2 terminal Is ...

Page 242: ...the ECT sensor 4 and the ECM 3 ECT sensor 4 signal line short circuit check 1 Turn the ignition switch OFF Disconnect the ECT sen sor 4 connector and the ECM connector B 2 Check for the continuity between the No 2 Red Green terminal of the ECT sensor 4 harness side 2P connector and the body ground Is there the continuity YES Repair short in the wire between the ECT sensor 4 and the engine ground N...

Page 243: ...itch OFF and connect the test har ness Hold the sensor connector connected 2 Disconnect the A F sensor 4P connector 3 Turn the ignition switch ON Measure the voltage between the test harness C 4 terminal and the engine ground Is there the battery voltage YES Perform 4 A F heater check NO Check the A F relay and replace if necessary If it is normal go to the step 4 4 Turn the ignition switch OFF an...

Page 244: ...e YES Substitute a known good ECM and recheck NO Repair open in the A F relay and the ECM 4 A F heater check 1 Turn the ignition witch OFF and disconnect the A F sensor 4P connector 2 Measure the resistance between the No 3 Black and No 4 Black terminals of the A F sensor s sensor side 4P connector Is the resistance 2 3 YES Perform 5 Heater line short circuit check NO Replace the A F sensor 5 Heat...

Page 245: ...ng MIL blinks 48 times 1 Symptom reproduction test 1 Reset the ECM 2 Start the engine and let it warm up by running the engine at 3 000 rpm for 5 minutes or more under no load Run the engine at idling for an additional one minute under no load 3 Check the MIL Does the MIL come ON YES Perform 2 A F sensor line open circuit check NO Temporary failure Disappeared 2 A F sensor line open circuit check ...

Page 246: ... ON but an engine failure of either of the following symptoms occurs at the engine start or during idling inspect the system s and part s in the numbered sequence Hard to start 1 Vacuum line 2 IAC valve P 5 95 Engine starts but stalls soon 1 Idle adjusting screw P 5 94 2 IAC valve P 5 95 3 Vacuum line Engine speed is higher than the specified idle speed after warming up 1 Vacuum line 2 IAC valve P...

Page 247: ... and check the idle speed 6 Adjust the idle speed by turning the adjusting screw If adjustment cannot be made check each vacuum tube for disconnection and collapse then check and clean the throttle body P 5 95 7 After adjustment connect the IAC valve 2P connector and clear the DTC P 5 14 or reset the ECM P 5 57 8 Run the engine at idling for 5 minutes or more then check the idle speed again 9 If t...

Page 248: ...the throttle bore and both ends of the throttle valve with a shop towel or equivalent material sprayed with the carburetor cleaner NOTICE 7 After cleaning install the throttle rod and the silencer chamber P 5 135 8 After assembly check the idle speed and adjust if nec essary P 5 94 IAC Valve Replacement 1 Remove the engine cover 2 Turn the ignition switch OFF and disconnect the IAC valve 2P connec...

Page 249: ... 19 2 Fuel strainer low pressure side P 3 15 3 Fuel line low pressure side P 5 104 4 Fuel pump low pressure side P 5 142 Engine tends to stall at hot restart of the engine 1 Vapor separator P 5 111 thru 5 127 High pressure fuel supply system Hard to start 1 Fuel line high pressure side P 5 104 2 Fuel pump high pressure side P 5 107 3 Fuel injector P 5 105 Engine starts but stalls soon 1 Fuel line ...

Page 250: ...s side 6P connector and the engine ground Is there the battery voltage YES Go to the step 6 NO Blown No 3 10A fuse or faulty ignition switch or open in the wire between the PGM FI main relay and the ignition switch 6 Measure the voltage between the No 2 White Yellow terminal of the harness side 2P connector and the engine ground Is there the battery voltage YES Go to the step 7 NO Blown No 3 10A f...

Page 251: ...n nector from the PGM FI main relay 2 Disconnect the ECM connectors A B and C 3 Check for the continuity between the No 6 Black ter minal of the harness side 6P connector and the engine ground Is there the continuity YES Repair short in the wire between the PGM FI main relay and the engine ground NO Go to the step 4 4 Measure the voltage between the No 3 White Yellow terminal of the fuse box side ...

Page 252: ...ck for the continuity between the terminals of the fuse box harness side 6P connector and ECM con nectors A and B Fuse Box 6P connector ECM connector A No 3 Light green Red No 13 Light green Red Fuse Box 6P connector ECM connector B No 3 Light green Red No 10 Light green Red Is there the continuity YES Go to the step 9 NO Repair open in the wire between the PGM FI main relay and the ECM 9 Turn the...

Page 253: ...21 terminal and the engine ground B 23 terminal and the engine ground B 27 terminal and the engine ground B 29 terminal and the engine ground Is there the continuity YES Repair open in the wire between the ECM and the injector NO Go to the step 5 5 Connect each injector 2P connector 6 Turn the ignition switch ON Check for the voltage between the test harness and engine ground B 21 terminal and the...

Page 254: ... ground No 2 Red of No 2 injector and engine ground No 2 Blue of the No 3 injector and engine ground No 2 Yellow of the No 4 injector and engine ground Is there the continuity YES Repair open in the wire between the ECM and the injector NO Go to the step 5 5 Connect the injector 2P connector 6 Turn the ignition switch ON Measure the voltage between the No 1 Yellow Black terminal of each injector h...

Page 255: ...ving the fuel pressure remove the service check bolt and replace the 6 mm sealing washer with a new one 5 Tighten the service check bolt to the specified torque TORQUE 12 N m 1 2 kgf m 9 lbf ft Fuel Pressure Measurement 1 Relieve the fuel pressure according to How to relive fuel pressure explained above 2 Remove the service check bolt and set the special tool fuel pressure gauge set in the threade...

Page 256: ...n P 5 106 When the fuel pressure is lower than the standard pressure Check the pressure regulator for proper operation Inspection P 5 106 Check the high pressure side fuel strainer for clogging Replacement P 3 18 Check the high pressure side fuel pump for proper oper ation Inspection P 5 107 6 After check replace the sealing washer with a new one and tighten the service check bolt to the specified...

Page 257: ...ote the following on replacement Relieve the fuel pressure according to How to relive fuel pressure P 5 102 then replace the fuel pipe hoses and tube Replace the O rings with the new ones Apply the engine oil to the O rings before installation Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Keep heat sparks and flame away Handle fuel only outdoo...

Page 258: ...nect the fuel injec tor connector of each cylinder and check the idle speed change and idling stability The fuel injector is normal when the idling condition changes If the idling condition does not change when the fuel injec tor connector is disconnected replace the fuel injector of the cylinder and recheck the idling condition 3 With the engine running at idling check for the operation sound of ...

Page 259: ...t rise connect the vacuum tube to the pressure regulator Pinch the pressure regula tor return hose that goes from the pressure regulator to the vapor separator a couple of times lightly and measure the fuel pressure again Protect the pressure regulator return hose by winding a shop towel or equivalent material around the hose and lightly pinch the hose with the pliers 7 If the measurement is outsi...

Page 260: ...d the body ground Is there the continuity YES Check the gasoline discharge volume NO Go to the step 5 5 Attach the positive tester lead to the Blue Yellow ter minal and the negative tester lead to the Black ter minal of the harness side connector Turn the ignition switch ON and be sure that there is battery voltage for approximately 2 seconds Is there the battery voltage YES Check the gasoline dis...

Page 261: ... or the discharge volume is too small check the following and replace the fuel pump P 5 121 Clogged high pressure side fuel filter Clogged high pressure side fuel hose pipe Faulty pressure regulator 5 If the high pressure side fuel pump is normal connect the 2P connector Set the connector on the connector bracket CONNECTOR BRACKET PRESSURE REGULATOR RETURN HOSE PRESSURE REGULATOR PRESSURE REGULATO...

Page 262: ...nect the IAB control valve 2P connector while running the engine at idling 3 Check the vacuum tube located above the IAB control valve for vacuum Is there the vacuum YES Perform 4 Ground line short circuit check NO Replace the IAB control valve 4 Ground line short circuit check 1 Turn the ignition switch OFF Disconnect the ECM con nector A and the IAB control valve 2P connector 2 Check for the con...

Page 263: ...hragm Inspection Do not try to adjust the full close stop screw Note that the shutter valve diaphragm must not be dis assembled If replacement is necessary replace as an assembly of the intake manifold assembly 1 Check the following Check the shutter valve shaft for play and the stuck shaft Check the shutter valve for smooth movement from the full open to the full close positions Check there is no...

Page 264: ...nd clip from the connector bracket 5 Unclamp the cover lock cable and the fuel tube 6 Remove the 6 x 25 mm flange bolt and disconnect the high pressure side fuel hose Remove the joint pipe and the O ring Replace the O ring with a new one 7 Disconnect the air vent tube and the pressure regulator return hose from the vapor separator Gasoline is highly flammable and explosive You can be burned or ser...

Page 265: ...s and one 8 x 30 mm flange bolt Remove the vapor sep arator assembly 5 112 8 Disconnect the fuel tube B from the low pressure side fuel pump 9 Disconnect the water tube from the crankcase 1 FUEL TUBE B 1 VAPOR SEPARATOR ASSEMBLY 2 8 mm WASHER 2 8 x 35 2 8 x 30 1 WATER TUBE ...

Page 266: ...d the O rings Replace the O rings on assembly 6 Remove the three 5 mm screws and remove the strainer cover O ring fuel strainer and the spring 7 VAPOR SEPARATOR STAY 6 3 5 x 420 mm DRAIN TUBE 4 4 5 x 55 mm FUEL TUBE 3 VAPOR SEPARATOR GROMMET 2 8 mm WASHER 5 TUBE CLIP B8 2 1 COLLAR 9 COLLAR 8 x 35 1 FUEL HOSE HIGH PRESSURE SIDE 3 FUEL STRAINER HIGH PRESSURE SIDE 8 5 mm SCREW 3 4 FILTER SPRING 7 SER...

Page 267: ...e pump cover and discard it Replace the O ring with a new one on assembly 9 Remove the pump holder 10 Remove the 4 mm screw and 4 mm washer then remove the pump harness assembly 5 114 4 PUMP HARNESS ASSEMBLY 5 CONNECTOR BRACKET 1 5 mm SCREW WASHER 4 8 PUMP COVER 7 PUMP HOLDER 2 4 mm SCREW 3 4 mm WASHER 6 O RING Do not reuse ...

Page 268: ...ump pump holder and the O ring Replace the O ring with a new one on assembly 14 Remove the four 6 x 25 mm flange bolts Remove the fuel pump case and the two O rings Replace the O rings with the new ones on assembly 3 PLATE 2 INSULATOR 6 SEAL RING 5 FUEL PUMP HIGH PRESSURE SIDE 4 PUMP HOLDER 2 FUEL PUMP CASE 1 O RING Do not reuse 6 x 25 4 1 O RING Do not reuse 1 O RING Do not reuse ...

Page 269: ...AT PIN 6 x 16 2 1 COVER GASKET Do not reuse 3 COVER GASKET Do not reuse 16 Remove the six 5 mm screw washers Remove the vapor separator cover and the cover gasket Replace the cover gasket with a new one on assembly 17 Remove the two screws Then remove the float float pin and the float valve 18 Remove the two 6 x 16 mm flange bolts and remove the vapor separator stay 15 Remove the eight 5 mm screw ...

Page 270: ...the specification check the float valve and valve seat for wear and damage 3 If the float valve and valve seat are normal adjust the float height by gently bending the brass float tab taking care not to damage the float FLOAT Check the float for damage and deformation and check for the gasoline in the float Check the float for smooth movement FLOAT VALVE VALVE SEAT Check the float valve head and t...

Page 271: ...EPARATOR COVER 16 VAPOR SEPARATOR CHAMBER 18 VAPOR SEPARATOR GROMMET 2 17 VAPOR SEPARATOR STAY 11 WATER JACKET COVER 10 5 mm SCREW WASHER 8 6 SCREW 2 8 5 mm COLLAR 8 9 5 mm WASHER 8 12 TUBE CLIP B12 15 TUBE CLIP 7 COVER GASKET Do not reuse 1 COVER GASKET Do not reuse 3 4 N m 0 35 kgf m 2 5 lbf ft 2 1 N m 0 21 kgf m 1 5 lbf ft 3 4 N m 0 35 kgf m 2 5 lbf ft 12 N m 1 2 kgf m 9 lbf ft ...

Page 272: ...ied torque TORQUE 12 N m 1 2 kgf m 9 lbf ft 5 Install the collars on the vapor separator grommet 6 Apply a thin coat of the engine oil to the new cover gasket and install the gasket in the groove in the vapor separator chamber securely 7 Install the vapor separator cover and tighten the 5 mm screw washers to the specified torque TORQUE 3 4 N m 0 35 kgf m 2 5 lbf ft 1 COLLAR 2 6 x 16 2 4 FLOAT VALV...

Page 273: ...e specified torque TORQUE 3 4 N m 0 35 kgf m 2 5 lbf ft 11 Connect the 7 x 400 mm water tube to the upper tube joint of the water jacket cover and secure the connection of the tube with the tube clip 12 Connect the 7 3 x 350 mm water tube to the lower tube joint of the water jacket cover and secure the connection of the tube with the tube clip B12 6 TUBE CLIP 7 TUBE CLIP B12 8 7 x 400 mm WATER TUB...

Page 274: ... 2 22 3 5 x 420 mm DRAIN TUBE 23 DRAIN SCREW 15 FUEL PUMP HIGH PRESSURE SIDE 10 CONNECTOR BRACKET 9 PUMP HARNESS ASSEMBLY 1 FUEL HOSE HIGH PRESSURE SIDE 3 FUEL STRAINER HIGH PRESSURE SIDE 17 O RING 2 Do not reuse 11 O RING Do not reuse 11 O RING Do not reuse 11 O RING Do not reuse 17 O RING 2 Do not reuse 2 5 mm SCREW WASHER 4 3 4 N m 0 35 kgf m 2 4 lbf ft 27 SERVICE CHECK BOLT 12 N m 1 2 kgf m 9 ...

Page 275: ... 12 N m 1 2 kgf m 9 lbf ft 4 Apply a thin coat of the engine oil to the new O ring and set it on the pump holder 5 Install the pump holder on the pump case Be sure to install it in the direction shown 6 Install the high pressure side fuel pump on the pump case Install by aligning the projection on the pump with the hole in the pump holder 6 x 25 4 1 PUMP HOLDER 2 FUEL PUMP CASE 1 HIGH PRESSURE SID...

Page 276: ...hem on the oil case 11 Set the seal ring at the discharge port of the pump 12 Apply a thin coat of the engine oil to the new O ring and set it at the discharge port of the pump 13 Connect the pump harness assembly terminals to the pump terminals as shown Connect the Blue Yellow wire terminal to the positive terminal of the pump and the Black wire terminal to the negative terminal of the pump 4 BLU...

Page 277: ...UE 3 4 N m 0 35 kgf m 2 4 lbf ft 18 Apply the engine oil to the new O rings and install them on the collar 19 Install the collar on the strainer cover 20 Set the fuel hose and secure it by tightening the 6 x 25 mm flange bolt 21 Using a new sealing washer tighten the service check bolt to the specified torque TORQUE 12 N m 1 2 kgf m 9 lbf ft 1 FUEL HOSE HIGH PRESSURE SIDE 5 COLLAR 2 O RING 2 3 SEA...

Page 278: ... stay 5 Set the vapor separator assembly on the engine and loose ly tighten it with the two 8 mm washers two 8 x 35 mm flange bolts and the one 8 x 30 mm flange bolt Align the projection of the vapor separator stay with the hole in the engine 6 Tighten the three 8 x 35 mm flange bolts and one 8 x 30 mm flange bolt to the specified torque TORQUE 26 N m 2 7 kgf m 20 lbf ft 8 VAPOR SEPARATOR ASSEMBLY...

Page 279: ...0 Connect the air vent tube to the vapor separator 11 Apply the engine oil to the new O ring and install it on the joint pipe 12 Set the joint pipe in the fuel tube and install the fuel hose 13 Tighten the 6 x 25 mm flange bolt to the specified torque BF135A BF150A 2 AIR VENT TUBE 1 TUBE CLIP 2 7 3 x 350 mm WATER TUBE 2 FUEL TUBE B 1 TUBE CLIP B12 3 FUEL HOSE HIGH PRES SURE SIDE 1 PRESSURE REGULAT...

Page 280: ...se with the clamps 17 After assembly check each fuel tube and clamp and check that they are not interfering with the neighboring parts 18 Turn the ignition switch ON Check that the fuel pump turns for 2 seconds and that there is no fuel water leakage 1 HARNESS BAND CLIP 5 COVER LOCK CABLE 6 FUEL TUBE 3 FUEL PUMP 2P CONNECTOR 2 CLAMPS 1 PRESSURE REGULA TOR RETURN HOSE 4 CONNECTOR BRACKET 4 FUEL TUB...

Page 281: ...ase 5 Remove the three 6 x 25 mm flange bolts and the three 6 mm washers Remove the silencer case 2 6 mm WASHER 3 2 SILENCER CASE 10 IAT SENSOR 3 IAT SENSOR 2P CONNECTOR 2 AIR FLOW TUBE CLAMP 1 SILENCER CASE 1 HARNESS BAND CLIP 6 x 25 3 4 COLLAR 3 5 GROMMET 3 8 VINYL TUBE 3 SILENCER DUCT GROMMET 6 AIR FLOW TUBE SPRING 7 AIR FLOW TUBE CLAMP 1 SENSOR GROMMET ASSEMBLY Install in the direction shown 9...

Page 282: ...he throttle rod Do not loosen the pivot lock nut 6 Remove one 8 x 60 mm flange bolt and remove the throttle body 7 Remove the throttle body gasket Replace the throttle body gasket with a new one The intake manifold assembly can be removed by skip ping the steps 6 and 7 i e with the throttle body mount ed 8 Disconnect the IAB control valve 2P connector 2 THROTTLE BODY 1 THROTTLE ROD 1 MAP SENSOR 3P...

Page 283: ...regulator vacuum tube from the intake manifold joint 10 Remove the two 8 x 55 mm flange bolts and remove the L side cover bracket The L side cover bracket can be removed without dis connecting the cover lock cable 1 PRESSURE REGULATOR VACUUM TUBE 2 INTAKE MANIFOLD JOINT 1 8 mm WASHER 2 8 mm FLANGE NUT 2 3 INTAKE MANIFOLD ASSEMBLY 1 L SIDE COVER BRACKET 8 x 55 2 8 x 35 5 ...

Page 284: ...LVE GASKET Do not reuse 9 THROTTLE BODY GASKET Do not reuse 8 x 45 2 22 N m 2 2 kgf m 16 lbf ft 8 x 60 4 5 x 12 2 SOLENOID VALVE TUBE ASSEMBLY Connect the solenoid valve tube to the top of the intake air cut off solenoid valve and the diaphragm tube to the lower joint of the intake air cut off solenoid valve 2 1 DIAPHRAGM TUBE 2 2 SOLENOID VALVE TUBE 2 3 UP 1 INTAKE MANIFOLD GASKET 4 ASSEMBLY Do n...

Page 285: ...ke manifold 2 5 x 18 mm SCREW 2 INTAKE MANIFOLD GASKET 5 TOP OF INTAKE MANIFOLD 4 PRESSURE REGULATOR RETURN HOSE 3 AIR VENT TUBE 1 PROJECTION 6 GROOVE 5 O RING Do not reuse 6 IDLE ADJUSTING SCREW ADJUSTMENT P 5 93 3 SET PLATE 1 MAP SENSOR ASSEMBLY Apply the engine oil to the new O ring and install it on the MAP sensor Install aligning the cutout in the set plate with the lib of the sensor as shown...

Page 286: ...gasket on the intake manifold 6 Install the throttle body and tighten the 8 x 60 mm flange bolts in the numbered sequence in two or three steps securely TORQUE 22 N m 2 2 kgf m 16 lbf ft 7 Install the throttle rod Note the throttle rod installation direc tion Don t loosen the lock nut of the throttle rod 8 Connect the IAB control valve 2P connector 1 8 mm FLANGE NUT 2 8 x 35 3 8 x 60 4 2 8 x 35 2 ...

Page 287: ...sor set plate 12 Connect the TP sensor 3P connector and set the harness band clip in the hole in the harness clip bracket E 13 Install the water level sensor connector on the harness clip bracket E BF135A BF150A 1 PRESSURE REGULATOR VACUUM TUBE 2 INTAKE MANIFOLD JOINT 1 L SIDE COVER BRACKET 8 x 55 2 1 MAP SENSOR 3P CONNECTOR 2 HARNESS BAND CLIP 2 WATER LEVEL SENSOR CONNECTOR 3 HARNESS CLIP BRACKET...

Page 288: ...ft lower sec tion of the silencer case 2 Tighten the three 6 x 25 mm flange bolts securely 3 Connect the crankcase breather tube 4 Fasten the air flow tube clamp securely 5 Connect the IAT sensor 2P connector and secure the har ness band clip in the hole in the silencer case 1 SILENCER CASE 4 SILENCER CASE 3 6 mm WASHER 3 5 WIRE HARNESS 2 CRANKCASE BREATHER TUBE 6 x 25 3 3 IAT SENSOR 2P CONNECTOR ...

Page 289: ...ng to HOW TO RELIEVE FUEL PRESSURE P 5 102 3 Remove the two 8 x 55 mm flange bolts and move the L side cover bracket out of position 4 Remove the three main harness clips from the respective clip brackets 5 Disconnect the connector from each injector 6 Remove the hose clip Clamp the pressure regulator return hose and the main wire harness 3 MAIN WIRE HARNESS 5 CLIP BRACKET 1 HOSE CLIP 4 INJECTOR 2...

Page 290: ...joint pipe and the O rings Replace the O rings on assembly 11 Release the fuel tube 2 places and the air vent tube 2 places from the 14 mm fuel tube clips 12 Remove the two 6 mm flange nuts and remove the fuel line assembly 1 AIR VENT TUBE 2 PRESSURE REGULATOR CONTROL TUBE 3 8 mm FLANGE NUT 2 4 14 mm FUEL TUBE CLIP 5 FUEL TUBE 3 FUEL HOSE HIGH PRESSURE SIDE 2 FUEL LINE ASSEMBLY 4 O RING 2 Do not r...

Page 291: ... Apply the engine oil to the new O rings and install them on the respective injectors Install the injectors aligning the projection with the groove in the fuel line 2 INJECTOR CLIP 4 3 14 mm FUEL TUBE CLIP 4 4 CLIP BRACKET 4 Do not reuse 6 7 47 x 3 6 mm O RING 4 5 FUEL TUBE 7 INJECTOR 4 1 INJECTOR 2 PROJECTION 3 INJECTOR CLIP 4 6 x 10 4 6 x 14 4 Do not reuse 1 7 85 x 3 53 mm O RING 4 ...

Page 292: ...base and the injector base gasket 4 Install the removed parts in the reverse order of removal Replace the injector base gasket on assembly Tighten the 8 x 25 mm flange bolts and the 8 mm flange nuts to the specified torque in the numbered sequence in a criss cross pattern in two or three steps TORQUE 24 N m 2 4 kgf m 18 lbf ft 2 INJECTOR BASE 24 N m 2 4 kgf m 18 lbf ft 3 8 mm FLANGE NUT 2 24 N m 2...

Page 293: ...el line 5 Install the pressure regulator and tighten the joint nut to the specified torque Install the pressure regulator in the direction shown TORQUE 27 N m 2 8 kgf m 20 lbf ft 6 Connect the pressure regulator return hose and secure it with the tube clamp D10 7 7 Connect the pressure regulator control tube 1 AIR VENT TUBE 2 STUD BOLT 2 3 8 mm FLANGE NUT 2 4 14 mm FUEL TUBE CLIP 6 FUEL TUBE 5 FUE...

Page 294: ...ghten the 6 x 25 mm flange bolt securely 11 Connect the 2P connector to each injector 12 Set the three clips of the main harness on the clip brackets 13 Clamp the pressure regulator return hose and the main wire harness with the hose clip 3 MAIN WIRE HARNESS 5 CLIP BRACKET 1 HOSE CLIP 4 INJECTOR 2P CONNECTOR 2 CLIP 3 FUEL HOSE HIGH PRESSURE SIDE Do not reuse 2 O RING 2 1 COLLAR 6 x 25 ...

Page 295: ... remove the fuel pump 5 Remove the O rings from the fuel pump Replace the O rings with the new ones on assembly b INSPECTION Push the plunger to check for smooth operation Replace the plunger if it is faulty Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately 1 L SI...

Page 296: ...re them respectively with the tube clip B1s 4 Install the L side cover bracket and tighten the 8 x 55 mm flange bolt securely 5 After assembly start the engine and check for the gasoline leakage from the low pressure side fuel pump 5 FUEL PUMP 2 FUEL PUMP 6 FUEL TUBE D 3 FUEL TUBE D 9 FUEL TUBE E 1 SENSOR HOSE CLIP 8 TUBE JOINT 2 TUBE CLIP B11 2 2 TUBE CLIP B1 2 7 TUBE CLIP B12 2 1 MARK 3 FUEL TUB...

Page 297: ...C from the water separator and fuel strainer 6 Remove the fuel strainer and water separator 7 Remove the 6 x 14 mm flange bolts and fuel strainer stay Installation is the reverse order of removal Gasoline is highly flammable and explosive You can be burned or seriously injured when handling fuel Keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately 1 CONNECTOR BRACKE...

Page 298: ...mm SCREW 3 6 SET PLATE 1 WATER SEPARATOR CUP WATER LEVEL SWITCH 3 BAFFLE PLATE 4 O RING 2 WATER SEPARATOR BODY 2 FUEL STRAINER BODY INSPECTION P 3 20 5 5 x 12 mm SCREW 3 6 SET PLATE 1 FUEL STRAINER LOW PRESSURE SIDE 4 STRAINER CUP 3 O RING FUEL STRAINER LOW PRESSURE SIDE ...

Page 299: ...eplace the O ring on assembly 3 Apply the engine oil to the new O ring and install it on the switch 4 Tighten the EOP switch to the specified torque TORQUE 22 N m 2 2 kgf m 16 lbf ft 5 After installation connect the switch connector 17 EOP ENGINE OIL PRESSURE SWITCH LOW PRESSURE SIDE a INSPECTION 1 Disconnect the low pressure side EOP switch terminal 2 Check for the continuity between the switch t...

Page 300: ...o not exceed the specified torque when tightening the EOP switch Overtightening will damage the cylinder block 6 Connect the EOP switch terminal NOTICE 18 ECT ENGINE COOLANT TEMPERATURE SENSOR 1 a REPLACEMENT 1 Disconnect the 2P connector of ECT sensor 1 2 Remove the ECT sensor 1 and the O ring Replace the O ring on assembly 3 Apply the engine oil to the new O ring and install it on the ECT sensor...

Page 301: ...pply the engine oil to the new O ring and install it on the ECT sensor 4 Tighten the overheat sensor to the specified torque TORQUE 12 N m 1 2 kgf m 9 lbf ft 5 After installation connect the ECT sensor 2P connector 1 ECT SENSOR 2 2P CONNECTOR 4 ECT SENSOR 3 2P CONNECTOR OF 3 ECT SENSOR 2 5 ECT SENSOR 3 7 ECT SENSOR 4 2P CONNECTOR 6 ECT SENSOR 4 2 O RING Do not reuse 2 O RING Do not reuse 2 O RING ...

Page 302: ...ter installation connect the knock sensor 1P connector 22 CMP CAMSHAFT POSITION SENSOR a REPLACEMENT 1 Remove the R L side covers 2 Disconnect the CMP sensor 3P connector 3 Remove the 6 x 16 mm flange bolt and remove the CMP sensor and the O ring Replace the O ring on assembly 4 Apply the engine oil to the new O ring and install it on the CMP sensor 5 Tighten the 6 x 16 mm flange bolt 6 After inst...

Page 303: ...nect the VTEC solenoid valve 1P connector and dis connect the connector from the harness band clip bracket C 2 Remove the three 6 x 55 mm flange bolts Remove the VTEC solenoid valve assembly gasket and the filter Replace the gasket and filter as an assembly of the VTEC solenoid valve assembly 3 Install the new gasket and filter on the VTEC solenoid valve 4 Install the VTEC solenoid valve assembly ...

Page 304: ...E REGULATOR CONTROL TUBE 9 SUSPENSION 8 PRESSURE REGULATOR RETURN HOSE 1 CRANKCASE BREATHER TUBE 3 VACUUM TUBE D 5 VACUUM TUBE C 7 AIR VENT TUBE A 10 AIR VENT TUBE E 12 VAPOR CHAMBER 11 TUBE CLIP 6 AIR VENT TUBE B 2 T JOINT ASSEMBLY Install with the mark toward the vacuum tube C side 4 CHECK VALVE 4 1 VACUUM TUBE C SIDE ...

Page 305: ...ctor from the harness band clip bracket BF150A Disconnect the A F sensor and VTEC solenoid valve connectors and remove the connectors from the har ness band clip bracket 4 Remove the harness band clip from the connector bracket 5 Remove the three 6 x 14 mm flange bolts and remove the connector bracket 1 CONNECTOR BRACKET 2 A F SENSOR CONNECTOR 3 VTEC SOLENOID VALVE CONNECTOR BF150A only 6 x 14 3 1...

Page 306: ...ge bolts and remove the valve assembly BF135A or the VTEC solenoid valve assembly BF150A 8 Remove the 6 x 22 mm flange bolts and remove the R side cover bracket 1 ECT SENSOR 3 CONNECTOR 1 VTEC SOLENOID VALVE ASSEMBLY BF150A or VALVE ASSEMBLY BF135A 1 R SIDE COVER BRACKET 6 x 55 3 6 x 22 3 ...

Page 307: ...RING Do not reuse 4 O RING Do not reuse 5 ECT SENSOR 3 12 N m 1 2 kgf m 9 lbf ft 8 ANODE METAL 2 1 EXHAUST MANIFOLD COVER GASKET 2 Do not reuse 10 x 45 3 6 x 22 4 6 x 14 10 x 75 3 4 EXHAUST MANIFOLD ASSEMBLY 9 6 x 18 mm SCREW 2 2 EXHAUST MANIFOLD COVER 2 7 EXHAUST MANIFOLD 1 GASKET Do not reuse 3 WATER TUBE CLAMP BRACKET DISASSEMBLY ASSEMBLY Remove install the A F sensor using the special tool TOR...

Page 308: ...ower left side and loosely tighten the 10 x 75 mm flange bolt as shown 4 Align the bolt holes by turning the gasket in the direction shown with the arrow Take care not to damage the gasket 6 x 14 3 6 x 55 3 1 CONNECTOR BRACKET 2 VTEC SOLENOID VALVE ASSEMBLY 5 EXHAUST MANIFOLD ASSEMBLY 1 EXHAUST MANIFOLD ASSEMBLY 10 x 45 3 10 x 75 2 6 GASKET 2 GASKET 10 x 75 Do not reuse 4 79 9 x 3 1 mm O RING Do n...

Page 309: ...specified torque in the numbered sequence in two or three steps TORQUE 39 N m 4 0 kgf m 29 lbf ft 6 Install the R side cover bracket and tighten the 6 x 22 mm flange bolts securely 7 Connect the 2P connector to the ECT sensor 3 1 R SIDE COVER BRACKET 1 ECT SENSOR 3 2 2P CONNECTOR 6 x 22 2 10 x 75 2 10 x 45 3 ...

Page 310: ...curely 10 BF135A Connect the A F sensor connector and set the connector on the harness band clip bracket C BF150A Connect the A F sensor and the VTEC solenoid valve connectors and set the connectors on the harness band clip bracket C 11 Set the harness band clip on the harness band clip bracket C 1 HARNESS BAND CLIP BRACKET C 1 VTEC SPOOL VALVE ASSEMBLY BF150A or VALVE ASSEMBLY BF135A 1 FILTER 2 G...

Page 311: ...Connect the following water hoses Water relief tube A B 7 x 90 mm tube 7 x 75 mm tube 7 x 120 mm tube Water tube E 1 WATER RELIEF TUBE A 6 WATER RELIEF TUBE B 2 7 x 120 mm TUBE 5 WATER TUBE E 3 7 x 90 mm TUBE 4 7 x 75 mm TUBE ...

Page 312: ...6 1 1 SILENCER DUCT 2 ALTERNATOR 6 ALTERNATOR 44 N m 4 5 kgf m 33 lbf ft 26 N m 2 7 kgf m 20 lbf ft 110 N m 11 2 kgf m 81 lbf ft 8 N m 0 8 kgf m 5 8 lbf ft ...

Page 313: ...re regulator control tube from the two 3 5 mm tube clips of the silencer duct assembly Remove the harness band clip that secures the main wire harness from the silencer duct assembly 2 Release the breather tube from the 18 5 mm clamp and the guide of the silencer duct assembly 2 SILENCER DUCT ASSEMBLY 7 3 5 mm TUBE CLIP 2 4 PRESSURE REGULATOR CONTROL TUBE 3 18 5 mm CLAMP 8 GUIDE 1 BREATHER TUBE 5 ...

Page 314: ...he silencer duct A on the silencer duct B and tighten the eight 5 x 12 mm self tapping screws securely 1 5 x 12 mm SELF TAPPING SCREW 8 2 18 5 mm CLAMP 3 SILENCER DUCT A 4 SILENCER DUCT B 5 DUCT GROMMET 4 6 DUCT COLLAR 4 6 x 25 4 11 6 mm WASHER 4 10 3 5 mm TUBE CLIP 2 8 PRESSURE REGULATOR CONTROL TUBE 9 BREATHER TUBE 7 HARNESS BAND CLIP ...

Page 315: ...ntrol tube with the two 3 5 mm tube clips of the silencer duct assembly Connect the pressure regulator control tube aligning the marked part on the tube with the end of the 3 5 mm tube clip P 2 71 5 Install the main wire harness harness band clip on the silencer duct assembly 6 Install the engine cover P 4 2 6 x 25 4 1 6 mm WASHER 4 2 SILENCER DUCT ASSEMBLY 2 SILENCER DUCT ASSEMBLY 7 3 5 mm TUBE C...

Page 316: ...arness and cable 1 Turn the ignition switch to the ON position and check that the alternator indictor light comes ON 2 If the alternator indicator light does not come ON disconnect the alternator 4P connector and short circuit the white blue terminal of the harness side connector to the ground 3 If the indicator light still does not come ON check the following Indicator light P 16 9 Main wire harn...

Page 317: ...t and move the alternator assembly to the engine side as full as it goes 1 8 mm FLANGE NUT 2 SPECIAL ADJUSTING BOLT 3 ALTERNATOR ASSEMBLY 10 x 80 4 Detach the alternator belt from the alternator pulley first then from the crankshaft pulley Remove the alternator belt Do not contaminate the alternator belt with oil and grease after removal Do not bend the alternator belt Store the belt by hanging it...

Page 318: ...e bolts and remove the alternator bracket 2 Remove the special adjusting bolt and remove the tensioner bolt 3 Remove the 6 x 16 mm flange bolt and remove the alternator stay 4 Remove the two 8 x 20 mm flange bolts and remove the engine hanger B 2 8 mm FLANGE NUT 10 x 80 1 ALTERNATOR ASSEMBLY 8 x 28 4 1 ENGINE HANGER B 8 x 20 2 6 x 16 3 ALTERNATOR STAY 5 TENSIONER BOLT 3 TENSIONER BOLT 4 SPECIAL AD...

Page 319: ... STAY 10 TENSIONER BOLT 8 SPECIAL ADJUSTING BOLT 11 ALTERNATOR BRACKET 3 ALTERNATOR ASSEMBLY 4 ALTERNATOR BELT 2 ALTERNATOR 4P CONNECTOR 6 ALTERNATOR FUSE CABLE 1 CRANKSHAFT PULLEY 5 8 mm FLANGE NUT 26 N m 2 7 kgf m 20 lbf ft 10 x 80 44 N m 4 5 kgf m 33 lbf ft 7 ALTERNATOR B TERMINAL WASHER NUT 8 N m 0 8 kgf m 5 8 lbf ft ...

Page 320: ... and the alternator pulley 3 PULLEY LOCK NUT 3 PULLEY LOCK NUT 2 22 mm OFFSET WRENCH 1 10 mm OFFSET WRENCH 3 Remove the 6 mm hex nut from the insulator bushing and remove the insulator bushing 4 Remove the three rear end cover bolts and the rear end cover 2 REAR END COVER 1 REAR END COVER BOLT 3 4 6 mm HEX NUT 4 ALTERNATOR PULLEY 3 INSULATOR BUSHING ...

Page 321: ... Remove the brush holder insulator from the brush holder assembly 1 BRUSH HOLDER INSULATOR 3 BRUSH HOLDER ASSEMBLY 2 4 x 6 mm SCREW 2 6 Remove the two 4 x 25 mm screw washers and the 4 x 6 mm screw from the IC regulator then remove the IC regulator 3 4 x 6 mm SCREW 2 4 x 25 mm SCREW WASHER 4 1 IC REGULATOR ...

Page 322: ...Replace the stator with a new one if a wire broke near the small hole in the rectifier assembly NOTICE 1 WIRE Straighten 2 4 x 6 mm SCREW 4 3 RECTIFIER ASSEMBLY 9 Remove the two 5 mm hex nuts and the two rear housing bolts Remove the rear housing 10 Remove the wave washer 4 WAVE WASHER 3 REAR HOUSING 2 REAR HOUSING BOLT 2 1 5 mm HEX NUT 2 ...

Page 323: ...ay before removal Replace the rear bearing with a new one if there is abnormal sound or play 13 Using a commercially available bearing puller as shown remove the rear bearing and washer Replace the rear bearing with new one on assembly Install a commercially available bearing puller with care not to damage the rotor fins NOTICE 1 BEARING PULLER Commercially available 2 REAR BEARING 3 WASHER 2 REAR...

Page 324: ... 16 Holding the stator drive end housing by attaching the wood blocks to both sides of the stator drive end housing as shown remove the front bearing from the stator using the special tools Replace the front bearing with a new one on assembly TOOLS Driver 07749 0010000 Attachment 24 x 26 mm 07746 0010700 Pilot 15 mm 07746 0040300 2 FRONT BEARING 4 STATOR DRIVE END HOUSING 1 DRIVER 07749 0010000 4 ...

Page 325: ...ss than the service limit replace the rotor 1 E GROUND P4 P3 P2 P1 P 1 B 1 E GROUND 2 Circuit diagram P1 P2 P3 P4 P 1 B STANDARD SERVICE LIMIT 10 5 mm 0 41 in 8 4 mm 0 33 in STANDARD SERVICE LIMIT 14 4 mm 0 57 in 14 0 mm 0 55 in RECTIFIER ASSEMBLY Inspect the rectifier assembly by removing it from the outboard motor Check for continuity between the B terminal and the respective P terminals P1 P2 P...

Page 326: ...NG Inspect the stator by removing it from the outboard motor 1 Check to see that there is continuity between the wires 2 Check to see that there is no continuity between each wire and the stator core 1 WIRES 1 WIRES 2 STATOR CORE ...

Page 327: ...TIFIER ASSEMBLY 19 WAVE WASHER 8 REAR HOUSING 9 REAR HOUSING BOLT 2 10 5 mm HEX NUT 5 BRUSH HOLDER INSULATOR 25 BRUSH HOLDER ASSEMBLY 4 4 x 6 mm SCREW 7 3 4 x 25 mm SCREW WASHER 2 24 IC REGULATOR 7 REAR END COVER 6 REAR END COVER BOLT 3 1 6 mm HEX NUT 2 INSULATOR BUSHING 16 ALTERNATOR PULLEY 18 BEARING COVER 17 PULLEY LOCK NUT 110 N m 11 2 kgf m 81 lbf ft ...

Page 328: ...ecial tools as shown TOOLS Driver 07749 0010000 Attachment 37 x 40 mm 07746 0010200 Pilot 15 mm 07746 0040300 1 DRIVER 07749 0010000 3 ATTACHMENT 37 x 40 mm 07746 0010200 2 PILOT 15 mm 07746 0040300 3 Install the retainer plate with the projections toward the front bearing and tighten it with the four screws 1 RETAINER PLATE 2 SCREW 4 4 STUD BOLTS 2 3 STATOR DRIVE END HOUSING 5 PROJECTIONS ...

Page 329: ... inner wall of the new rear bearing and install it on the rotor shaft 6 Attach the special tool to the rear bearing side and install the rear bearing on the rotor using the hydraulic press TOOLS Attachment 52 x 55 mm 07746 0010400 Driver 22 mm I D 07746 0020100 Attachment 15 mm I D 07746 0020200 3 REAR BEARING 1 REAR BEARING 2 WASHER 3 ROTOR SHAFT 3 ATTACHMENT 52 x 55 mm 07746 0010400 1 DRIVER 22 ...

Page 330: ...nd install the wave washer 9 Pass the wire through the respective four holes in the rear housing Install the rear housing on the stator drive end housing and tighten the two 5 mm hex nuts and the rear housing bolts securely Install the rear housing aligning the outer side of the wave washer with the outer side of the bearing 3 STATOR DRIVE END HOUSING 1 BEARING COVER 4 ROTOR 2 SLIP RINGS 6 WAVE WA...

Page 331: ... wire broke near the hole in the rectifier assembly NOTICE 1 WIRE Bend along the hole 13 Assemble the brush holder insulator with the brush holder assembly 14 Position the brush holder assembly on the IC regulator and loosely tighten the 4 x 6 mm screw Loosely tighten the 4 x 6 mm screw so that the brush holder does not move 1 BRUSH HOLDER INSULATOR 4 IC REGULATOR 3 BRUSH HOLDER ASSEMBLY 2 4 x 6 m...

Page 332: ... has been tightened loosely in step 14 Take care not to damage the rotor shaft slip rings with the brush during installation NOTICE 16 Install the rear end cover and tighten the three rear end cover bolts securely 17 Install the insulator bushing and tighten the 6 mm hex nut securely 1 4 x 6 mm SCREW 2 2 4 x 25 mm SCREW WASHER 2 4 SLIP RINGS 3 IC REGULATOR BRUSH HOLDER ASSEMBLY 2 REAR END COVER 1 ...

Page 333: ...NATOR PULLEY 8 x 28 4 1 ENGINE HANGER B 8 x 20 2 6 x 16 4 ALTERNATOR STAY 6 TENSIONER BOLT 5 SPECIAL ADJUSTING BOLT 2 ALTERNATOR BRACKET 3 PROJECTION i ALTERNATOR BRACKET ASSEMBLY 1 Tighten the alternator bracket with the four 8 x 28 mm flange bolts securely 2 Tighten the 6 x 16 mm flange bolt securely while pushing the alternator stay against the projection on the alternator bracket 3 Position th...

Page 334: ...ions of the alternator bracket and loosely tighten the 10 x 80 mm flange bolt 1 ALTERNATOR BELT 2 CRANKSHAFT PULLEY 3 ALTERNATOR PULLEY 3 Install the alternator belt on the crankshaft pulley first then on the alternator pulley Do nut turn the crankshaft pulley counterclockwise NOTICE 2 8 mm FLANGE NUT 10 x 80 1 ALTERNATOR ASSEMBLY 3 TENSIONER BOLT 4 Between the projections ...

Page 335: ...r 4P connector to the alternator assembly 8 Connect the alternator fuse cable to the alternator assembly and loosely tighten the alternator B terminal washer nut 9 Tighten the alternator B terminal washer nut to the specified torque so that the alternator fuse cable is connected at 60 from the horizontal line as shown TORQUE 8 N m 0 8 kgf m 5 8 lbf ft 10 Install the following parts Silencer duct P...

Page 336: ... m 6 5 kgf m 47 lbf ft 64 N m 6 5 kgf m 47 lbf ft 64 N m 6 5 kgf m 47 lbf ft 44 N m 4 5 kgf m 33 lbf ft 44 N m 4 5 kgf m 33 lbf ft 44 N m 4 5 kgf m 33 lbf ft 44 N m 4 5 kgf m 33 lbf ft 26 N m 2 7 kgf m 20 lbf ft 26 N m 2 7 kgf m 20 lbf ft 26 N m 2 7 kgf m 20 lbf ft ...

Page 337: ...emove the following parts Extension case lower rubber mount P 14 89 Oil case P 14 94 2 Be sure that the engine is held vertically and remove the following parts Starter motor P 18 1 Starter cable P 18 15 Shift link bracket neutral switch P 17 11 3 Remove the two 6 x 20 mm flange bolts and remove the seal holder assembly from the engine assembly 4 Disconnect the air vent tube A and the oil tube fro...

Page 338: ...nting case 6 Disconnect the water relief tube C from the relief valve cover P 8 6 7 Remove the two 10 mm cap nuts and the 10 x 70 mm flange bolt from the engine assembly 8 Remove the two 8 x 55 mm flange bolts and the 12 x 83 mm flange bolt 1 EXHAUST GUIDE 8 x 30 4 1 10 mm CAP NUTS 10 x 70 8 x 55 12 x 83 ...

Page 339: ...om the mounting case 2 10 x 16 mm DOWEL PIN 1 ENGINE ASSEMBLY 7 14 x 20 mm DOWEL PIN 9 MOUNTING CASE GASKET 3 EXHAUST GUIDE GASKET 8 OIL PUMP RUBBER 8 x 100 10 x 80 10 x 110 2 6 12 x 70 mm HEX BOLT 5 12 x 130 mm HEX BOLT 2 4 12 mm WASHER 3 Be sure that the hoist hooks are set on the three engine hangers securely Lift up the engine assembly while holding the engine vertically NOTICE 11 Remove the t...

Page 340: ...0 lbf ft 8 x 100 26 N m 2 7 kgf m 20 lbf ft 10 x 80 44 N m 4 5 kgf m 33 lbf ft 10 x 110 2 44 N m 4 5 kgf m 33 lbf ft 8 12 x 70 mm HEX BOLT 64 N m 6 5 kgf m 47 lbf ft 12 x 83 64 N m 6 5 kgf m 47 lbf ft 10 x 70 44 N m 4 5 kgf m 33 lbf ft 8 x 55 2 26 N m 2 7 kgf m 20 lbf ft 4 EXHAUST GUIDE GASKET 7 12 x 130 mm HEX BOLT 2 64 N m 6 5 kgf m 47 lbf ft 1 10 mm CAP NUT 2 44 N m 4 5 kgf m 33 lbf ft ...

Page 341: ...sket and the exhaust guide on the mounting case and loosely tightem the four 8 x 30 mm flange bolts 6 Install the 10 x 16 mm dowel pin 14 x 20 mm dowel pin mounting case gasket and the oil pump rubber on the mounting case 7 Lower the engine assembly slowly while aligning the two 10 x 55 mm stud bolts and the shift shaft B with the respective installation holes in the engine assembly Take care not ...

Page 342: ...rom the underside of the mounting case Tighten to the specified torque TORQUE 26 N m 2 7 kgf m 20 lbf ft 11 Loosely tighten each bolt and washer at the designated places from the underside of the mounting case Then tighten them to the specified torque in the numbered sequence in two or three steps TORQUE 12 x 70 mm hex bolt 12 x 130 mm hex bolt 64 N m 6 5 kgf m 47 lbf ft 10 x 80 mm flange bolt 10 ...

Page 343: ...T SHAFT B 2 OIL TUBE 8 x 55 10 x 70 12 x 83 1 10 mm CAP NUTS 14 Connect the air vent tube A and the oil tube to the mounting case 15 Tape around the stepped part of the shift shaft B to protect it 16 Install the seal holder assembly on the engine assembly and tighten the two 6 x 20 mm flange bolts P 17 23 Set the starter cable and the alternator fuse cable in the cable bracket A P 17 23 17 Install...

Page 344: ...8 1 1 THERMOSTAT 2 WATER RELIEF TUBE RELIEF VALVE 3 FLUSH VALVE 8 THERMOSTAT RELIEF VALVE FLUSH VALVE 12 N m 1 2 kgf m 9 lbf ft 12 N m 1 2 kgf m 9 lbf ft ...

Page 345: ...ase the breather tube from the 18 5 mm clamp of the harness clip bracket B 6 Remove the two 6 x 14 mm flange bolts from the harness clip bracket B With the harness clip bracket B raised a little remove the harness band clip and the wire harness clip from the harness clip bracket B 7 WIRE HARNESS CLIP 6 HARNESS BAND CLIP 6 x 14 2 6 x 22 3 8 BREATHER TUBE 5 18 5 mm CLAMP 4 HARNESS CLIP BRACKET B 11 ...

Page 346: ...sembly Thermostat for cylinder head The thermostat for the cylinder head can be identified with the purple paint or two grooves on the thermostat NOTICE Thermostat for cylinder block The thermostat for the cylinder block can be identified with no paint or three grooves on the thermostat 1 Thermostat for cylinder head 3 PURPLE PAINT 2 GROOVES 2 places 2 GROOVES 3 places 1 Thermostat for cylinder bl...

Page 347: ...ll a new 9 5 x 1 9 mm O ring on the ECT sensor 2 and 4 respectively Apply a liquid sealant ThreeBond 1201 or 1215 or equivalent to the threads and seat of each sensor 6 Install the ECT sensor 2 and 4 and tighten them to the specified torque TORQUE 12 N m 1 2 kgf m 9 lbf ft 7 Set the 18 5 mm clamp harness band clip and the wire harness clip on the harness clip bracket B and tighten the two 6 x 14 m...

Page 348: ...mp B 3 Disconnect the water relief tube B from the exhaust guide b DISASSEMBLY OF WATER RELIEF TUBE ASSEMBLY 1 Disconnect the water relief tube A and B from the 4 way joint 2 Disconnect the 7 x 90 mm tube and the 7 x 120 mm tube from the fuel tube joint 3 Disconnect the fuel tube joint from the 7 x 75 mm tube 4 Disconnect the 7 x 75 mm tube and the water tube E from the 4 way joint 10 7 x 75 mm TU...

Page 349: ...m TUBE 2 WATER RELIEF TUBE C 5 7 x 40 mm TUBE 7 RELIEF VALVE COVER 6 x 22 2 6 T JOINT 3 RUBBER PART 1 RELIEF VALVE 2 RELIEF VALVE SPRING 1 TUBE CLAMP D10 5 6 c WATER RELIEF TUBE C RELIEF VALVE DISASSEMBLY 1 Disconnect the 7 x 160 mm tube 7 x 40 mm tube and the water relief tube C from the engine side 2 Disconnect each tube from the T joint 3 Remove the two 6 x 22 mm flange bolts and remove the rel...

Page 350: ...Connect the 7 x 160 mm tube 7 x 40 mm tube and the water relief tube C to the T joint and clamp each tube with the tube clamp D10 5 4 Set the tube clamp D10 5 on the side of each tube where is opposite to the other end connected to the T joint and connect each tube to the engine side Clamp each tube with the tube clamp D10 5 NOTICE 3 RELIEF VALVE 4 RELIEF VALVE COVER O RING 8 7 x 160 mm TUBE 2 WAT...

Page 351: ...Connect the water relief tube A to the 4 way joint so that its installation angle is approximately 90 as shown 4 Set the tube clamp D25 0s on the water relief tube A and B 5 Set the tube clamp D25 0s in the position 8 mm from the end of each tube as shown 8 mm 0 3 in 8 mm 0 3 in 1 TUBE CLAMP D25 0 2 3 WATER RELIEF TUBE B SIDE 6 WATER RELIEF TUBE B 1 WATER RELIEF TUBE A SIDE 2 WATER RELIEF TUBE A 4...

Page 352: ...direction shown i e toward the intake manifold side Clamp the water relief tube A and the main wire harness with the water tube clamp 3 Connect the 7 x 90 mm tube and the water tube E to the engine side 4 Connect the 7 x 120 mm tube to the engine side and set the tube clamp D10 5s with the lugs toward down 5 Install the following parts L R engine under covers P 4 14 Engine cover P 4 2 Start the en...

Page 353: ... the flush plug cap from the 8 x 300 mm tube 3 Remove the 6 x 16 mm flange bolt then remove the flush valve cover flush valve and the flush valve spring Do not reuse the 16 mm O ring on the flush valve cover Replace with a new one on assembly 3 MOUNT CASE 2 7 x 200 mm TUBE 1 TUBE CLAMP D10 5 2 7 FLUSH VALVE COVER 6 16 mm O RING 4 FLUSH VALVE SPRING 5 FLUSH VALVE 6 x 16 11 FLUSH PLUG CAP 10 WATER H...

Page 354: ...cover 2 Install the flush valve spring and the flush valve on the flush valve cover Note the installation direction of the flush valve 3 Tighten the flush valve cover with the 6 x 16 mm flange bolt securely 4 Install the tube clip B12 5s flush plug cap water hose joint A and the water seal on the 8 x 300 mm tube Connect the 8 x 300 mm tube to the flush valve cover and clamp the tube with the tube ...

Page 355: ... N m 1 2 kgf m 9 lbf ft 12 N m 1 2 kgf m 9 lbf ft 12 N m 1 2 kgf m 9 lbf ft 12 N m 1 2 kgf m 9 lbf ft 12 N m 1 2 kgf m 9 lbf ft 22 N m 2 2 kgf m 16 lbf ft 22 N m 2 2 kgf m 16 lbf ft 245 N m 25 0 kgf m 181 lbf ft 12 N m 1 2 kgf m 9 lbf ft 12 N m 1 2 kgf m 9 lbf ft ...

Page 356: ...s clip bracket C Disconnect the connectors 2 Remove the three harness band clips from the harness clip bracket C 3 Remove the three 6 x 14 mm flange bolts from the harness clip bracket C and remove the harness clip bracket C 4 Remove the two 8 x 20 mm flange bolts from the engine hanger B and remove the engine hanger B 5 Remove the main wire harness from the recesses of the chain case 6 x 14 3 2 H...

Page 357: ...r attachment HEX 50 mm 07JAB 0010400 Socket wrench 19 mm 07JAA 001020A 8 Remove the 16 x 49 mm bolt washer and remove the crankshaft pulley and the 4 5 x 21 mm key 1 CKP SENSOR 3P CONNECTOR 2 CKP SENSOR 3 4 5 x 21 mm KEY 2 CRANKSHAFT PULLEY 1 16 x 49 mm BOLT WASHER 3 SOCKET WRENCH 19 mm 07JAA 001020A 1 PULLEY HOLDER ATTACHMENT HEX 50 mm 07JAB 0010400 2 HANDLE 07JAB 001020B ...

Page 358: ... 11 Pushing the cam chain tensioner arm toward the cam chain tensioner align the hole in the lock with the hole in the cam chain and insert the pin of 1 5 mm in O D into the hole Do not remove the pin of 1 5 mm in O D from the cam chain tensioner before installing the cam chain tensioner NOTICE 6 x 25 3 6 x 28 10 1 6 x 37 SH BOLT 10 x 43 3 3 CHAIN CASE 4 O D 1 5 mm PIN 5 Align hole in lock with ho...

Page 359: ...ve the tensioner pivot bolt and the cam chain tensioner arm 14 Remove the three 6 x 20 mm flange bolts and remove the cam chain guide 15 Remove the two 8 x 110 mm flange bolts and remove the cam chain guide B 1 CAM CHAIN TENSIONER 2 CAM CHAIN TENSIONER ARM 6 x 30 2 2 CAM CHAIN GUIDE 6 x 20 3 3 CAM CHAIN TENSIONER ARM 1 TENSIONER PIVOT BOLT 1 CAM CHAIN GUIDE B 8 x 110 2 ...

Page 360: ... Remove the crank pulser plate from the crankshaft 17 Remove the cam chain Keep the cam chin away from any magnetic parts and devices after removal NOTICE 9 6 1 CRANKSHAFT 2 CRANK PULSER PLATE 1 CAM CHAIN ...

Page 361: ... commercially available oil seal remover Replace the 43 x 58 x 7 mm oil seal with a new one on assembly 2 Remove the CKP sensor and the chain case cover from the chain case Replace the CKP sensor at the 15 x 1 9 mm O ring with a new one on assembly 6 x 16 2 CHAIN CASE COVER 3 43 x 58 x 7 mm OIL SEAL 4 15 x 1 9 mm O RING 5 CKP SENSOR 1 CHAIN CASE 6 x 14 3 ...

Page 362: ... CHAIN CASE 12 N m 1 2 kgf m 9 lbf ft 6 x 14 3 12 N m 1 2 kgf m 9 lbf ft 1 6 x 38 SH BOLT 12 N m 1 2 kgf m 9 lbf ft 6 x 28 10 12 N m 1 2 kgf m 9 lbf ft 6 x 25 3 12 N m 1 2 kgf m 9 lbf ft 6 x 30 2 245 N m 25 0 kgf m 181 lbf ft 2 16 x 49 mm BOLT WASHER 12 N m 1 2 kgf m 9 lbf ft 4 6 x 31 mm SPECIAL BOLT 2 22 N m 2 2 kgf m 16 lbf ft 17 TENSIONER PIVOT BOLT 12 N m 1 2 kgf m 9 lbf ft 6 x 20 3 22 N m 2 2...

Page 363: ...move the old liquid gasket and apply the liquid gasket again before assembly NOTICE 2 ASSEMBLY CHAIN CASE ASSEMBLY 1 Apply soapy water to the outer surface of a new 43 x 58 x 7 mm oil seal Using the special tools drive in the 43 x 58 x 7 mm oil seal until it seats on the chain case as shown After installation apply grease to the oil seal lip TOOLS Driver 07749 0010000 Attachment 52 x 55 mm 07746 0...

Page 364: ... lbf ft 5 Position a new 15 x 1 9 mm O ring on the CKP sensor and apply engine oil to the O ring Install the CKP sensor by tightening the 6 x 16 mm flange bolt securely 6 x 16 2 CHAIN CASE COVER 4 43 x 58 x 7 mm OIL SEAL 5 15 x 1 9 mm O RING 6 CKP SENSOR 3 Apply grease to the lip 1 CHAIN CASE 12 N m 1 2 kgf m 9 lbf ft 6 x 14 3 ...

Page 365: ...E 2 Install the cam chain guide and tighten the three 6 x 20 mm flange bolts to the specified torque TORQUE 12 N m 1 2 kgf m 9 lbf ft 3 Install the cam chain tensioner arm and tighten the tensioner pivot bolt to the specified torque TORQUE 22 N m 2 2 kgf m 16 lbf ft 3 CYLINDER BLOCK 2 MARKS 1 CRANKSHAFT SPROCKET 2 CAM CHAIN GUIDE 6 x 20 3 3 CAM CHAIN TENSIONER ARM 1 TENSIONER PIVOT BOLT ...

Page 366: ...e exhaust camshaft while holding the hexagonal part of the intake and exhaust camshafts with the wrench or equivalent tool and thereby aligning the alignment marks on both the intake and exhaust camshaft sprockets Install the cam chain aligning the mid point of the two color plates with the punch mark on the intake exhaust camshaft sprockets Check that the color plate one of the crankshaft sprocke...

Page 367: ...e specified torque TORQUE 12 N m 1 2 kgf m 9 lbf ft Remove the 1 5 mm pin 9 Wipe up oil etc from the crankshaft outer surface with a clean shop towel Install the crankshaft pulser plate on the crankshaft with the OUT SIDE mark facing out 3 CRANKSHAFT Wipe up oil etc from crankshaft surface with a clean shop towel 1 OUT SIDE MARK 2 CRANK PULSER PLATE 5 CUTOUTS 4 RECESS 3 CAM CHAIN TENSIONER ARM 2 C...

Page 368: ...n guide B and tighten the two 8 x 110 mm flange bolts to the specified torque TORQUE 22 N m 2 2 kgf m 16 lbf ft 11 Install the new chain case gasket on the chain case 1 CHAIN CASE GASKET 1 CAM CHAIN GUIDE B 8 x 110 2 2 CHAIN CASE ...

Page 369: ...of the liquid gasket again to the part A shown in the drawing i e apply to the bead of the liquid gasket applied before Assemble the chain case within 5 minutes after applying the liquid gasket If it has been left for 5 minutes or longer remove the old liquid gasket and apply the liquid gasket again before assembly NOTICE 2 CHAIN CASE 1 CHAIN CASE O RING 3 Apply a bead of liquid gasket 2 PART A 2 ...

Page 370: ...he standard torque TORQUE 6 x 38 mm SH flange bolt 1 6 x 28 mm flange bolts 10 6 x 31 mm special bolts 2 6 x 25 mm flange bolts 3 12 N m 1 2 kgf m 9 lbf ft STANDARD TORQUE 10 x 43 mm flange bolts 3 39 N m 40 kgf m 29 lbf ft Do not touch the surfaces coated with the liquid gasket Take care not to slide the chain case during installation as it makes the thickness of the liquid gasket uneven Take car...

Page 371: ...ean shop towel sprayed with the degreasing cleaning agent 20 Apply the engine oil to the threads and the seating surface of the 16 x 49 mm bolt washer 21 Position the 4 5 x 21 mm key and the crankshaft pulley on the crankshaft then loosely tighten the 16 x 49 mm bolt washer 5 CRANKSHAFT PULLEY 4 16 x 49 mm BOLT WASHER 6 CRANKSHAFT 1 Wipe up contamination 2 Apply engine oil 3 Degrease with degreasi...

Page 372: ...B Pulley holder attachment HEX 50 mm 07JAB 0010400 Socket wrench 19 mm 07JAA 001020A TORQUE 245 N m 25 0 kgf m 181 lbf ft 23 Connect the CKP sensor 3P connector to the CKP sensor 2 SOCKET WRENCH 19 mm 07JAA 001020A 3 PULLEY HOLDER ATTACHMENT HEX 50 mm 07JAB 0010400 1 HANDLE 07JAB 001020B 1 CKP SENSOR 3P CONNECTOR 2 CKP SENSOR ...

Page 373: ...nect the A F sensor 4P connector and the VTEC solenoid valve 1P connector BF150A only and install them on the harness clip bracket C 28 Install the following parts Cylinder head cover P 10 40 Thermostat P 8 4 Alternator belt P 3 30 Silencer duct P 6 4 L R engine under cover P 4 14 Engine cover P 4 2 3 RECESSES OF CHAIN CASE 2 MAIN WIRE HARNESS 8 x 20 2 1 ENGINE HANGER B 6 x 14 3 2 HARNESS BAND CLI...

Page 374: ...D ASSEMBLY ASSEMBLY 11 CYLINDER HEAD ASSEMBLY INSTALLATION 12 CAMSHAFT ROCKER ARM ASSEMBLY 13 CYLINDER HEAD COVER ASSEMBLY 14 CYLINDER HEAD COVER INSTALLATION 10 CYLINDER HEAD VALVE 12 N m 1 2 kgf m 9 lbf ft 113 N m 11 5 kgf m 83 lbf ft 72 N m 7 3 kgf m 53 lbf ft 22 N m 2 2 kgf m 16 lbf ft 39 N m 4 0 kgf m 29 lbf ft 22 N m 2 2 kgf m 16 lbf ft 22 N m 2 2 kgf m 16 lbf ft 12 N m 1 2 kgf m 9 lbf ft 12...

Page 375: ...olts then remove the R side cover bracket assembly from the engine assembly 3 Disconnect the fuel tube B and the fuel tube D from the fuel pump low pressure side Before disconnecting the fuel tube B and the fuel tube D clamp the fuel tubes with the tube clips to prevent gasoline leakage NOTICE 6 x 22 2 1 R SIDE COVER BRACKET ASSEMBLY 1 BREATHER TUBE 2 MAIN WIRE HARNESS 3 FUEL PUMP Low pressure sid...

Page 376: ...e projection on the cylinder head cover to the other side 6 Remove the six 6 mm hex cap nuts and the six head cover washers then remove the cylinder head cover 1 OIL TUBE 2 MOUNTING CASE 1 WATER RELIEF TUBE A 3 CYLINDER HEAD COVER 3 6 mm HEX CAP NUT 2 HEAD COVER WASHER 6 1 CYLINDER HEAD COVER 2 PROJECTION ...

Page 377: ...LT 2 10 OIL TUBE 9 TUBE CLIP D32 5 8 IGNITION COIL 4 7 6 x 25 mm SOCKET BOLT 4 4 6 mm HEX CAP NUT 6 11 SPARK PLUG TUBE SEAL 4 INSPECTION Check the seal lip for a break or other damage Replace if necessary 1 HEAD COVER GASKET INSPECTION Check for damage and deterioration Replace if necessary 12 N m 1 2 kgf m 9 lbf ft ...

Page 378: ... parts Crankshaft pulley cam chain P 9 2 3 Disconnect the CMP sensor 3P connector Remove the harness band clip from the clip bracket F 4 Remove the 6 x 16 mm flange bolts from the No 5 rocker shaft holder then remove the CMP sensor and the CMP hole plug 5 Remove the 15 2 x 1 9 mm O rings from the CMP sensor and the CMP hole plug Replace the O rings with the new ones on assembly 6 Secure the hex pa...

Page 379: ... flange bolt from the intake camshaft sprocket Remove the intake camshaft sprocket from the intake camshaft 9 Secure the hex part of the exhaust camshaft with a wrench or equivalent tool 2 14 mm SEALING BOLT 1 CAMSHAFT COLLAR 2 INTAKE CAMSHAFT SPROCKET 3 INTAKE CAMSHAFT 1 EXHAUST CAMSHAFT 1 VTC FLANGE BOLT ...

Page 380: ... from the exhaust camshaft sprocket then remove the exhaust camshaft sprocket from the exhaust camshaft 12 Loosen the rocker arm s lock nut then loosen the valve adjusting screw fully 1 CMP PULSE PLATE 2 14 mm SEALING BOLT 2 EXHAUST CAMSHAFT SPROCKET 1 EXHAUST CAMSHAFT 10 x 32 2 VALVE ADJUSTING SCREW 1 VALVE ADJUSTING LOCK NUT ...

Page 381: ...ange bolts 12 6 x 32 mm flange bolt 1 6 x 20 mm flange bolts 2 15 Remove the cam chain guide B camshaft holder and the intake and exhaust camshafts Remove the 10 dowel pins 8 x 110 2 6 10 x 16 mm DOWEL PIN 10 8 x 90 12 6 x 32 6 x 20 2 4 HEAD CAVER BOLT 6 3 CAM CHAIN GUIDE B 5 CAMSHAFT HOLDER 4 1 INTAKE CAMSHAFT 2 EXHAUST CAMSHAFT 1 2 3 4 5 6 7 w e p a y u 8 9 r t s d i o 0 q ...

Page 382: ...collar and the CMP pulse plate 17 Insert the bolts into the rocker shaft holders and remove the rocker arm assembly from the cylinder head assembly 1 EXHAUST CAMSHAFT 5 INTAKE CAMSHAFT 4 14 mm SEALING BOLT 2 3 CAMSHAFT COLLAR 2 CMP PULSE PLATE 1 ROCKER ARM ASSEMBLY 2 BOLT 4 3 10 x 16 mm DOWEL PIN 10 ...

Page 383: ...N 10 14 CAM CHAIN GUIDE B 20 No 1 CAMSHAFT HOLDER 19 No 2 CAMSHAFT HOLDER 18 No 3 CAMSHAFT HOLDER 17 No 4 CAMSHAFT HOLDER 15 No 5 CAMSHAFT HOLDER 3 VTC FLANGE BOLT 113 N m 11 5 kgf m 83 lbf ft 10 x 32 72 N m 7 3 kgf m 53 lbf ft 6 x 20 2 12 N m 1 2 kgf m 9 lbf ft 9 14 mm SEALING BOLT 2 11 CLIP BRACKET F 6 x 14 8 x110 2 22 N m 2 2 kgf m 16 lbf ft 8 x 90 12 22 N m 2 2 kgf m 16 lbf ft 6 x 32 12 N m 1 ...

Page 384: ... before removing or installing the rocker arm assembly from on the cylinder head NOTICE Apply molybdenum disulfide oil to the outer surface of the intake exhaust rocker shafts on assembly 2 INTAKE ROCKER ARM ASSEMBLY 4 No 1 ROCKER SHAFT HOLDER 5 No 2 ROCKER SHAFT HOLDER 6 No 3 ROCKER SHAFT HOLDER 7 No 4 ROCKER SHAFT HOLDER 9 No 5 ROCKER SHAFT HOLDER 10 RUBBER BAND 3 EXHAUST ROCKER ARM 11 INTAKE RO...

Page 385: ...r installing the rocker arm assembly from on the cylinder head NOTICE Apply molybdenum disulfide oil to the outer surface of the intake exhaust rocker shafts on assembly 2 INTAKE ROCKER ARM ASSEMBLY 4 No 1 ROCKER SHAFT HOLDER 5 No 2 ROCKER SHAFT HOLDER 6 No 3 ROCKER SHAFT HOLDER 7 No 4 ROCKER SHAFT HOLDER 9 No 5 ROCKER SHAFT HOLDER 10 RUBBER BAND 3 EXHAUST ROCKER ARM 11 INTAKE ROCKER SHAFT 8 EXHAU...

Page 386: ... 2 PRI 2 PRI 3 MID 4 SEC 4 SEC BF135A 6 EXHAUST CAMSHAFT 5 CAM CHAIN 5 CAM CHAIN 5 CAM CHAIN STANDARD SERVICE LIMIT IN PRI SEC 32 626 32 931 mm 1 2845 1 2965 in IN MID 35 369 35 654 mm 1 3925 1 4037 in EX 33 927 34 212 mm 1 3357 1 3469 in STANDARD SERVICE LIMIT No 1 28 955 28 970 mm 1 1400 1 1405 in No 2 No 5 28 925 28 940 mm 1 1388 1 1394 in STANDARD SERVICE LIMIT No 1 No 5 29 000 29 024 mm 1 141...

Page 387: ...m flange bolt 8 x 110 mm flange bolt 22 N m 2 2 kgf m 16 lbf ft 6 x 20 mm flange bolt 6 x 32 mm flange bolt 12 N m 1 2 kgf m 9 lbf ft NOTICE 5 Remove the camshaft holder Measure the width of the pressed part of the plastigauge using a scale printed on the bag of the plastigauge Measure the widest width on the plastigauge NOTICE 1 PLASTIGAUGE 2 PLASTIGAUGE 1 SCALE STANDARD SERVICE LIMIT No 1 0 030 ...

Page 388: ...s of the camshaft 2 Install the dial indicator and measure the camshaft runout by turning the camshaft ROCKER SHAFT O D 1 Dowel pin is at your side STANDARD SERVICE LIMIT 0 05 0 20 mm 0 4 mm 0 002 0 008 in 0 02 in STANDARD SERVICE LIMIT 0 03 mm 0 001 in Max 0 4 mm 0 02 in 4 If the measurement exceeds the service limit replace the camshaft holder rocker shaft holder and the cylinder head as a set a...

Page 389: ...ker arm assembly at low lift side Before performing inspection with the special tool s check that the secondary rocker arm moves independently See Check of stuck rocker arm assembly at high lift side Check with the special tool s can be made on the following conditions At cylinder head disassembly Engine power drops significantly at high rpm but the cause of the problem cannot be identified by fol...

Page 390: ...essure gradually 4 Remove the 10 mm sealing bolt from the No 1 camshaft holder and install the air stopper special tool 5 Remove the two mounting bolts of the No 2 and No 3 camshaft holders intake side and install the special tool as shown TOOLS Air supply 07LAJ PR30102 VTEC air adapter 07ZAJ PNA0101 VTEC air stopper 07ZAJ PNA0200 Air joint adapter 07ZAJ PNA0300 Install the VTEC air adapter specia...

Page 391: ...ve air pressure as the pistons can jump out of the rocker arm After removing the rocker arm assembly tie the assembly with a rubber band or equivalent to prevent each component of the assembly from missing Note to remove the rubber band after installation 2 If the pistons do not move smoothly replace the rocker arm as an assembly 3 Apply the engine oil to the rocker arm pistons on assembly NOTICE ...

Page 392: ... lever to the N Neutral position 2 Turn the crankshaft pulley clockwise until it puts the No 1 piston at the top dead center of its compression stroke P 3 12 Remove the following pars Crankshaft pulley cam chain P 9 2 Camshaft rocker arm P 10 5 Throttle body intake manifold P 5 129 Fuel line assembly P 5 136 Injector base P 5 139 Exhaust manifold P 5 152 3 Loosen the 11 x 155 mm bolt washers in th...

Page 393: ...itable material to prevent damage to the valve 2 Change the attachment of the special tool as shown TOOLS Valve spring compressor 07757 0010000 Valve spring compressor attachment 07757 PJ10100 NOTICE NOTICE 1 PLASTIC HAMMER 2 SOCKET 3 ADAPTER 2 VALVE SPRING COMPRESSOR 07757 0010000 2 VALVE SPRING COMPRESSOR 07757 0010000 1 VALVE SPRING COMPRESSOR ATTACHMENT 07757 PJ10100 1 VALVE SPRING COMPRESSOR ...

Page 394: ...he valve spring retainer valve spring valve valve spring seat and the valve stem seal Check the valve for chipping and excessive carbon deposits Clean the valve if necessary Replace the valve stem seal on assembly 1 VALVE SPRING RETAINER 4 VALVE SPRING SEAT 3 VALVE STEM SEAL 2 VALVE SPRING 5 VALVE 1 VALVE KEEPER 2 ...

Page 395: ...NG 8 16 EXHAUST VALVE 8 5 EXHAUST VALVE GUIDE 8 15 INTAKE VALVE GUIDE 8 8 LOST MOTION 8 10 VALVE KEEPER 32 1 14 x 20 mm DOWEL PIN 2 6 x 20 2 6 x 20 18 VTC STRAINER 3 VTC HOLE PLUG 19 VTC FILTER 2 CYLINDER HEAD GASKET 4 CYLINDER HEAD 9 11 x 155 mm BOLT WASHER 10 Used bolt 39 N m 4 0 kgf m 29 lbf ft 90 90 New bolt 39 N m 4 0 kgf m 29 lbf ft 90 90 98 COMPONENTS DRAWING ...

Page 396: ...e valve guides to remove any carbon deposits before measuring Measure and record each valve guide I D Turn the valve guide reamer 5 525 mm special tool clockwise and never turn it counterclockwise Continue to turn the reamer as you lift it from the valve guide NOTICE 1 VALVE FACE 2 VALVE O D 1 OVERALL LENGTH 1 VALVE GUIDE REAMER 5 525 mm 07HAH PJ70100 STANDARD SERVICE LIMIT IN EX 49 64 mm 1 954 in...

Page 397: ...31 in 0 004 in If the stem to guide clearance exceeds the service limit replace the valve and the valve guide as a set P 10 26 Recondition the valve seat whenever replacing the valve guide P 10 28 NOTICE STANDARD SERVICE LIMIT IN EX 1 25 1 55 mm 2 0 mm 0 049 0 061 in 0 08 in If the valve seat width is under the standard or over the service limit or if the valve seat is too high low recondition the...

Page 398: ...height NOTICE NOTICE CYLINDER HEAD HEIGHT 11 x 155 mm BOLT WASHER CYLINDER HEAD BOLT O D 1 Measure the bolt O D at two points as shown 1 MEASUREMENT POINT 3 FEELER GAUGE 2 STRAIGHT EDGE 50 mm 2 0 in 45 mm 1 8 in SERVICE LIMIT 0 05 mm 0 002 in Min SERVICE LIMIT 10 6 mm 0 42 in STANDARD SERVICE LIMIT 103 95 104 05 mm 4 093 4 096 in Cylinder head reconditioning procedure Apply Prussian Blue compound ...

Page 399: ... valve guide for damage Replace any damaged valve guide VALVE GUIDE REAMING For best results be sure the cylinder head is at room temperature before reaming valve guides 1 Coat the reamer and valve guide with cutting oil 2 Rotate the reamer clockwise through the valve guide for the full length of the reamer 3 Continue to rotate the reamer clockwise while removing it from the valve guide TOOL Valve...

Page 400: ...e bore it should be straight round and centered in the valve guide insert the valve and check operation If the valve does not operate smoothly the guide may have been bent during installation Replace the valve guide if it is bent or damaged 6 Check the Valve Stem to Valve Guide Clearance P 10 24 ...

Page 401: ...y area of the seat that is not concentric 1 VALVE FACE 3 Using a 45 cutter remove enough material to produce a smooth and concentric seat Follow the Valve Seat Cutter Manufacturer s Instructions Turn the cutter clockwise never counterclockwise Continue to turn the cutter as you lift it from the valve seat TOOLS Cutter holder 5 5 mm 07781 0010101 Valve seat cutter 45 35 mm 07780 0010400 Valve seat ...

Page 402: ...sable felt tipped marker ink to the valve faces Insert the valves and then lift them and snap them closed against their seats several times Be sure the valve does not rotate on teh seat The seating surface as shown by the transferred marking compound should have good contact all the way around 7 Lap the valves into their seats using a hand valve lapper and lapping compound commercially available T...

Page 403: ...inner wall of a new valve stem seal Set the valve stem seal in the special tool and push it straight into the valve guide by hand TOOL Stem seal driver 07PAD 0010000 Note that the valve stem seal A intake side has the white spring and the valve stem seal B exhaust side has the black spring Do not confuse them on assembly NOTICE 3 VALVE 1 VALVE SPRING SEAT 5 VALVE STEM SEAL 4 VALVE STEM SEAL A INTA...

Page 404: ...57 PJ10100 Take care not to let the special tools contact the cylinder head Do not compress the valve springs more than necessary as it causes weak valve spring The valve keepers can be installed in the groove in the valve stem by applying a small mount of grease to the valve keepers and adhering them to the groove in the valve stem NOTICE 6 Tap on the valve stem head lightly with a plastic hammer...

Page 405: ...d and cylinder block mounting surfaces 2 Install the two dowel pins on the cylinder block Install a new cylinder head gasket on the cylinder block by setting the projection of the cylinder head gasket in the position shown 3 Align the mark on the crankshaft sprocket with the mark on the cylinder block NOTICE 4 Align the dowel pins on the cylinder block with the dowel pin installation positions of ...

Page 406: ...n increments of 90 When a bolt is replaced with a new one tighten additionally to 98 TORQUE Used bolt 39 N m 4 0 kgf m 29 lbf ft 90 90 New bolt 39 N m 4 0 kgf m 29 lbf ft 90 90 98 7 Install the following parts Exhaust manifold P 5 155 Injector base P 5 139 Fuel line assembly P 5 140 Throttle body intake manifold P 5 132 Camshaft rocker arm P 10 34 Crankshaft pulley cam chain P 9 11 Cylinder head c...

Page 407: ...ins on the cylinder head assembly 4 Insert the bolts into each of the rocker shaft holders and install the rocker arm assembly on the cylinder head assembly NOTICE 5 Apply engine oil to the threads and seat of the 14 mm sealing bolts Install the camshaft collar on the intake camshaft and the CMP pulse plate on the exhaust camshaft then tighten the 14 mm sealing bolts to the specified torque TORQUE...

Page 408: ...olders and the cam chain guide B 8 Apply engine oil to the threads and seat of each bolt and loosely tighten to the designated position respectively Install the camshafts with the No 1 piston at the top dead center of the compression stroke i e dowel pin at your side NOTICE 9 Tighten each bolt to the specified torque in the numbered sequence in two or three steps TORQUE Head cover bolt 8 x 90 mm f...

Page 409: ...in the exhaust camshaft sprocket with the dowel pin on the exhaust camshaft Tighten the 10 x 32 mm flange bolt on the exhaust camshaft to the specified torque TORQUE 72 N m 7 3 kgf m 53 lbf ft 12 Secure the hex part of the intake camshaft with a wrench or equivalent tool 1 EXHAUST CAMSHAFT SPROCKET 3 EXHAUST CAMSHAFT 2 CONCAVE 4 DOWEL PIN 1 EXHAUST CAMSHAFT 1 INTAKE CAMSHAFT ...

Page 410: ...the CMP hole plug intake side in the CMP sensor holes in the No 5 rocker shaft holder Tighten the CMP sensor and CMP hole plug with the 6 x 16 mm flange bolts respectively 16 Connect the CMP sensor 3P connector and set the harness band clip on the clip bracket F 17 Install the crankshaft pulley cam chain P 9 11 and adjust the valve clearance P 3 9 18 Install the following parts Cylinder head cover...

Page 411: ...t on the cylinder head cover 10 38 13 CYLINDER HEAD COVER ASSEMBLY 1 Install the spark plug tube seals on the cylinder head cover noting the installation direction of the seal 2 SPARK PLUG TUBE SEAL 4 1 Spark plug tube seal installation direction 3 CYLINDER HEAD COVER 2 CYLINDER HEAD COVER 1 HEAD COVER GASKET ...

Page 412: ...jection on the oil tube with the projection on the cylinder head cover Check that the oil tube is inserted in the cylinder head cover securely 5 Set the tube clip D32 5 with the lugs in the position shown 4 OIL TUBE 1 CYLINDER HEAD COVER 3 TUBE CLIP D32 5 5 LUGS 2 PROJECTIONS ...

Page 413: ...TICE 3 Apply soapy water to the spark plug tube seal lip of the cylinder head cover 4 Install the cylinder head cover on the cylinder head by aligning the spark plug tube with the spark plug tube seal Check the spark plug tube seals for breakage and fatigue when installing the cylinder head cover After installation check that the spark plug tube seals are not turned up but they are set properly Wi...

Page 414: ...9 lbf ft 8 Move the water relief tube A from the other side of the projection on the cylinder head cover to your side 9 Connect the fuel tube B and D to the fuel pump low pressure side 1 WATER RELIEF TUBE A 3 CYLINDER HEAD COVER 2 PROJECTION 3 FUEL PUMP Low pressure side 2 FUEL TUBE B 4 FUEL TUBE D 1 TUBE CLIPS Commercially available ...

Page 415: ...e bolts 12 Connect the breather tube and the main wire harness to the cylinder head cover Route the main wire harness so it sets on the projections on the cylinder head cover securely 13 Install the following parts Ignition coil spark plug P 3 8 L R engine under covers P 4 14 Engine cover P 4 2 NOTICE 3 BREATHER TUBE 1 PROJECTION 2 MAIN WIRE HARNESS 2 MAIN WIRE HARNESS 1 OIL TUBE 2 MOUNTING CASE 6...

Page 416: ...GE 2 OIL PUMP 3 FLYWHEEL 11 OIL PUMP FLYWHEEL 32 N m 3 3 kgf m 24 lbf ft 39 N m 4 0 kgf m 29 lbf ft 22 N m 2 2 kgf m 16 lbf ft 8 N m 0 8 kgf m 5 8 lbf ft 12 N m 1 2 kgf m 9 lbf ft 118 N m 12 0 kgf m 87 lbf ft 12 N m 1 2 kgf m 9 lbf ft ...

Page 417: ...gh pressure side 2P connector Remove the ECT sensor and the EOP switch high pressure side 1 13 x 1 5 mm O RING 2 9 5 x 1 9 mm O RING 9 22 5 x 24 mm O RING 2 Do not reuse 10 WATER TUBE E INSPECTION Check the tube for deterioration Replace the tube if necessary 8 7 x 160 mm TUBE 7 OIL FILTER FLANGE 6 OIL FILTER 12 N m 1 2 kgf m 9 lbf ft 3 ECT SENSOR 12 N m 1 2 kgf m 9 lbf ft 5 EOP SWITCH LOW PRESSUR...

Page 418: ...he specified torque and connect the ECT sensor 2P connector TORQUE 12 N m 1 2 kgf m 9 lbf ft 3 Apply engine oil to the 9 5 x 1 9 mm O ring and install it on the EOP switch high pressure side 4 Tighten the EOP switch high pressure side to the specified torque and connect the EOP switch high pressure side 2P connector TORQUE 22 N m 2 2 kgf m 16 lbf ft 3 EOP SWITCH High pressure side 2 ECT SENSOR 1 9...

Page 419: ... the 7 x 160 mm tube to the oil filter flange and clamp the tube with the tube clamp D10 5 securely 8 Apply engine oil to the O ring that is set in the new oil filter 9 Clean the oil filter mounting part of the engine side oil filter flange and apply engine oil to the stud Tighten the oil filter by hand 1 O RING 1 OIL FILTER 2 TUBE CLAMP D10 5 2 4 7 x 160 mm TUBE 1 WATER TUBE E 6 x 25 4 6 x 20 3 O...

Page 420: ...e EOP switch low pressure side to the specified torque using the torque wrench TORQUE 8 N m 0 8 kgf m 5 8 lbf ft Use the torque wrench to tighten the EOP switch low pressure side Do not overtighten the EOP switch as it can damage the oil filter flange 13 Connect the EOP switch terminal to the EOP switch low pressure side 14 Add the specified amount of the engine oil P 3 2 After adding the oil chec...

Page 421: ...ve 8 x 32 mm flange bolts Remove the oil pump body assembly oil pump body gasket 14 x 20 mm dowel pin and the 10 x 16 mm dowel pin Replace the oil pump body gasket with a new one on assembly 8 x 32 5 2 14 x 20 mm DOWEL PIN 3 10 x 16 mm DOWEL PIN 1 OIL PUMP BODY ASSEMBLY 4 OIL PUMP BODY GASKET ...

Page 422: ...6 mm FLAT SCREW 9 9 46 x 60 x 9 mm OIL SEAL INSPECTION Check the oil seal lip for breakage or other damage Replace if necessary Do not reuse Replace on assembly 1 31 x 46 x 7 mm OIL SEAL INSPECTION Check the oil seal lip for breakage or other damage Replace if necessary Do not reuse Replace on assembly 7 18 mm SEALING BOLT 39 N m 4 0 kgf m 29 lbf ft ...

Page 423: ...L PUMP BODY I D OIL PUMP BODY DEPTH STANDARD SERVICE LIMIT 84 000 84 030 mm 3 3071 3 3083 in STANDARD SERVICE LIMIT 9 520 9 550 mm 0 3748 0 3760 in OUTER ROTOR HEIGHT STANDARD SERVICE LIMIT 9 480 9 500 mm 0 3732 0 3740 in ...

Page 424: ...MIT 0 04 0 16 mm 0 20 mm 0 002 0 006 in 0 008 in OUTER ROTOR TO PUMP BODY CLEARANCE STANDARD SERVICE LIMIT 0 02 0 07 mm 0 12 mm 0 001 0 003 in 0 005 in OUTER ROTOR TO OIL PUMP BODY SIDE CLEARANCE STANDARD SERVICE LIMIT 0 14 0 19 mm 0 20 mm 0 006 0 007 in 0 008 in ...

Page 425: ... 4 Clean the inner rotor and the outer rotor thoroughly Apply engine oil to the inner and outer rotors and install them on the oil pump body Note to install the rotors in the same direction as the direction of the rotors noted on disassembly 5 Install the two dowel pins and the oil pump cover on the oil pump body and tighten the nine 6 x 16 mm flat screws Check that the rotors move smoothly 2 18 m...

Page 426: ... Oil seal driver attachment 72 mm 07947 6340201 Oil seal driver 07947 SB00100 8 After installing the oil seals apply grease to each oil seal lip 8 x 32 5 2 14 x 20 mm DOWEL PIN 3 10 x 16 mm DOWEL PIN 1 OIL PUMP BODY ASSEMBLY 4 OIL PUMP BODY GASKET 1 46 x 60 x 9 mm OIL SEAL 2 Oil seal installation direction 2 Oil seal installation direction 5 31 x 46 x 7 mm OIL SEAL 8 OIL PUMP BODY 6 OIL PUMP COVER...

Page 427: ...the 10 mm nuts Do not damage the mating surface of the oil pump body gasket on the cylinder block Check that the special tool is set on the ring gear securely TOOL Ring gear holder 070PB ZY60100 NOTICE 4 Remove the eight 8 mm special bolts and the flywheel boss 5 Remove the eight 12 mm bolts and the flywheel 6 Remove the special tool 1 10 mm BOLT 2 3 10 mm NUT 2 2 8 mm SPECIAL BOLT 8 1 FLYWHEEL BO...

Page 428: ...NG 1 FLYWHEEL BOSS 3 FLYWHEEL 8 x 32 5 4 14 x 20 mm DOWEL PIN 5 10 x 16 mm DOWEL PIN 7 OIL PUMP BODY ASSEMBLY 6 OIL PUMP BODY GASKET 2 12 mm BOLT 8 118 N m 12 0 kgf m 87 lbf ft 8 8 mm SPECIAL BOLT 8 32 N m 3 3 kgf m 24 lbf ft ...

Page 429: ...uence in two or three steps TORQUE 118 N m 12 0 kgf m 87 lbf ft 5 Clean the flywheel and flywheel boss mating surfaces thoroughly with the degreasing cleaning agent 6 Apply engine oil to the threads and seating surface of the 8 mm special bolts 7 Install the flywheel boss on the flywheel and loosely tighten the eight 8 mm special bolts 8 Tighten the 8 mm special bolts to the specified torque in th...

Page 430: ...MBLY 3 INSPECTION 4 BALANCER CASE ASSEMBLY ASSEMBLY 5 CRANKCASE BALANCER CASE ASSEMBLY INSTALLATION 12 CRANKCASE BALANCER 12 N m 1 2 kgf m 9 lbf ft 22 N m 2 2 kgf m 16 lbf ft 22 N m 2 2 kgf m 16 lbf ft 44 N m 4 5 kgf m 33 lbf ft 12 N m 1 2 kgf m 9 lbf ft 44 N m 4 5 kgf m 33 lbf ft ...

Page 431: ...sets the No 1 piston at the top dead center of its compression stroke P 3 12 Remove the following parts Crankshaft pulley cam chain P 9 2 3 Remove the engine from the outboard motor P 7 2 4 Remove the fifteen 6 x 25 mm flange bolts from the crankcase 5 Insert the screwdriver into the recesses of the crankcase and raise the crankcase little by little Take care not to damage the crankcase and lower ...

Page 432: ...at the special tool is inserted in the balancer case assembly securely NOTICE 10 Remove the two 10 x 105 mm flange bolts 8 x 75 mm flange bolt and the 8 x 50 mm flange bolt Remove the balancer case assembly and the two dowel pins 2 CHAIN GUIDE BOLT 2 3 BALANCER CHAIN GUIDE 6 x 14 3 1 BALANCER CHAIN TENSIONER 4 BALANCER CHAIN 3 CRANKSHAFT SPROCKET 1 DRIVEN SPROCKET 2 10 x 30 mm BOLT WASHER 10 x 105...

Page 433: ...20 2 6 x 14 2 CABLE BRACKET B 5 18 x 13 mm DOWEL PIN 1 CRANKCASE 4 13 x 20 mm DOWEL PIN 2 15 OIL CAP 6 x 25 15 12 N m 1 2 kgf m 9 lbf ft 10 x 105 2 44 N m 4 5 kgf m 33 lbf ft 16 26 x 2 7 mm O RING Do not reuse 8 x 75 8 x 50 22 N m 2 2 kgf m 16 lbf ft 7 CHAIN GUIDE BOLT 2 12 N m 1 2 kgf m 9 lbf ft 9 10 x 30 mm BOLT WASHER 44 N m 4 5 kgf m 33 lbf ft COMPONENTS DRAWING 22 N m 2 2 kgf m 16 lbf ft ...

Page 434: ...BALANCER SHAFT 6 8 x 10 mm DOWEL PIN 2 3 12 x 16 mm DOWEL PIN 2 2 BALANCER SHAFT BEARING 4 INSPECTION Check the bearings for damage and replace if necessary After replacing the bearing check the oil clearance P 12 6 8 x 55 3 27 N m 2 8 kgf m 20 lbf ft 6 x 32 3 12 N m 1 2 kgf m 9 lbf ft 6 x 25 2 12 N m 1 2 kgf m 9 lbf ft ...

Page 435: ...al Do not turn the balancer shaft while checking oil clearance 4 Reinstall the rear balancer holder and tighten the bolts to the specified torque P 12 7 5 Remove the rear balancer holder Measure the width of the pressed part of the plastigauge using the scale printed on the bag of the plastigauge Measure the widest width on the plastigauge NOTICE NOTICE 6 If the measurement exceeds the service lim...

Page 436: ...s on each of the front and rear balancer shaft gears as shown 4 Apply engine oil to the threads and seat of the 8 x 55 mm flange bolts 5 Install the four dowel pins and the rear balancer holder on the front balancer holder Tighten the bolts to the specified torque TORQUE 8 x 55 mm flange bolt 27 N m 2 8 kgf m 20 lbf ft 6 x 32 mm flange bolt 6 x 25 mm flange bolt 12 N m 1 2 kgf m 9 lbf ft 5 FRONT B...

Page 437: ... Install the crankshaft sprocket on the crankshaft aligning the projection on the crankshaft sprocket with the concave in the crankshaft After installation check that the mark on the crankshaft sprocket aligns with the mark on the cylinder block The No 1 piston is at the top dead center of its compression stroke when the mark on the crankshaft sprocket aligns with the mark on the cylinder block NO...

Page 438: ...hain on the crankshaft sprocket while aligning the mark on the crankshaft sprocket with the color plate 1 place of the balancer chain 7 Install the driven sprocket on the balancer chain while aligning the alignment mark on the driven sprocket with the color plates 2 places of the balancer chain 3 REAR BALANCER SHAFT 2 MAINTENANCE HOLE 3 ALIGNMENT MARK 2 PROJECTION 1 REAR BALANCER SHAFT 1 CRANKSHAF...

Page 439: ...ssembly 9 Install the balancer chain guide on the lower block and tighten the two chain guide bolts to the specified torque TORQUE 12 N m 1 2 kgf m 9 lbf ft 10 Pushing the balancer chain tensioner against the balancer chain install the balancer chain tensioner on the balancer holder Tighten the three 6 x 14 mm flange bolts 5 DRIVEN SPROCKET 4 REAR BALANCER SHAFT 2 CONCAVE 3 PROJECTION 1 10 x 30 mm...

Page 440: ...ot tighten the three bolts of the chain case crankcase mating side and do not install the crankshaft pulley 14 Clean the crankcase and lower block mating surfaces thoroughly with the degreasing cleaning agent 15 Apply a bead ø2 0 3 0 mm ø0 08 0 12 in of the liquid gasket ThreeBond 1280B or equivalent to the indicated area of the crankcase Assemble the crankcase within 5 minutes after applying the ...

Page 441: ...e specified torque in the numbered sequence in two to three steps TORQUE 12 N m 1 2 kgf m 9 lbf ft 19 Install the engine on the outboard motor P 7 6 20 Install the following parts Crankshaft pulley P 9 17 Electric parts main wire harness P 18 14 17 19 and 27 Silencer duct P 6 4 Throttle body intake manifold P 5 132 Silencer case P 5 135 L R engine under covers P 4 14 Engine cover P 4 2 1 CRANKCASE...

Page 442: ...1 DISASSEMBLY 2 INSPECTION 3 BEARING SELECTION 4 ASSEMBLY 13 CYLINDER BLOCK CRANKSHAFT PISTON 29 N m 3 0 kgf m 22 lbf ft 56 20 N m 2 0 kgf m 14 lbf ft 90 26 N m 2 7 kgf m 20 lbf ft 26 N m 2 7 kgf m 20 lbf ft ...

Page 443: ...assembly P 12 2 1 Loosen the bolts in the numbered sequence in two or three steps 2 Remove the four 8 x 50 mm flange bolts and ten 8 x 35 mm flange bolts from the lower block 3 Loosen the ten 11 x 95 mm washer bolts in the numbered sequence in two or three steps 4 Remove the ten 11 x 95 mm washer bolts from the lower block 5 Insert the screwdriver into the recesses of the lower block and raise the...

Page 444: ...ed by blowing with the compressed air replace the lower block orifice with a new one Remove the blockage with care not to damage the oil passage of the lower block orifice 10 Check that the piston is at the bottom dead center of its stroke If not move the piston to the bottom dead center by turning the crankshaft 11 Remove the connecting rod bolts then remove the connecting rod cap connecting rod ...

Page 445: ...age cannot be removed by blowing with the compressed air replace the oil jet orifice with a new one Remove the blockage with care not to damage the oil passage of the oil jet orifice NOTICE NOTICE 16 Remove the oil jet bolt from the No 1 No 2 cylinder of the cylinder block and remove the oil jet body 17 Remove the piston assembly from the cylinder by pushing the piston assembly with the handle of ...

Page 446: ...iston pin clip end gap with the cutout in the piston pin hole Do not damage the piston pin clip installation groove NOTICE 3 Remove the piston pin clips from the cut out at both sides of the piston Remove the piston pin clips with care not to let them jump out of position NOTICE 4 Warm up the piston assembly to approximately 70 C 158 F and remove the piston pin 2 PISTON RING 3 PISTON RING PLIERS C...

Page 447: ...WASHER 2 9 OIL JET BODY 2 10 CYLINDER BLOCK 17 LOWER BLOCK 2 LOWER MAIN BEARING 5 14 13 x 14 mm DOWEL PIN 10 16 18 x 22 mm DOWEL PIN 4 80 x 98 x 10 mm OIL SEAL 1 11 x 95 mm BOLT WASHER 10 29 N m 3 0 kgf m 22 lbf ft 56 7 OIL JET BOLT 2 18 LOWER BLOCK ORIFICE 10 N m 1 0 kgf m 7 lbf ft 8 x 50 4 26 N m 2 7 kgf m 20 lbf ft 8 x 35 10 26 N m 2 7 kgf m 20 lbf ft 16 N m 1 6 kgf m 12 lbf ft ...

Page 448: ...12 mm DOWEL PIN 2 9 CONNECTING ROD BEARING 2 5 CONNECTING ROD 10 PISTON PIN 4 PISTON 3 PISTON PIN CLIP 2 2 PISTON RING 1 TOP RING 14 SECOND RING 12 OIL RING 13 SIDE RAIL 2 11 SPACER 8 CONNECTING ROD BOLT 2 20 N m 2 0 kgf m 14 lbf ft 90 ...

Page 449: ...linder I D PISTON TO CYLINDER CLEARANCE 11 mm 0 4 in 1 O D 90 5 NO 1 CYLINDER 4 NO 4 CYLINDER 1 TOP 2 MIDDLE 3 BOTTOM 1 TOP 2 MIDDLE 3 BOTTOM X Y STANDARD SERVICE LIMIT A 86 98 86 99 mm 86 93 mm 3 4244 3 4248 in 3 4224 in B 86 97 86 98 mm 86 92 mm 3 4240 3 4244 in 3 4220 in STANDARD SERVICE LIMIT A or l 87 01 87 02 mm 87 07 mm 3 4256 3 4260 in 3 4279 in B or ll 87 00 87 01 mm 87 07 mm 3 4252 3 425...

Page 450: ... mm 0 13 mm 0 0016 0 0026 in 0 005 in The oil rings are the combination rings Replace the top ring second ring and the oil rings as a set when either top or second ring needs replacement STANDARD SERVICE LIMIT TOP 0 20 0 35 mm 0 6 mm 0 008 0 014 in 0 02 in SECOND 0 50 0 65 mm 0 75 mm 0 020 0 026 in 0 030 in OIL 0 20 0 70 mm 0 8 mm 0 008 0 028 in 0 031 in If the end gap is larger than the service l...

Page 451: ...ce STANDARD SERVICE LIMIT 21 960 21 963 mm 0 8646 0 8647 in CONNECTING ROD SMALL END I D STANDARD SERVICE LIMIT 23 969 23 982 mm 0 9437 0 9442 in PISTON PIN O D STANDARD SERVICE LIMIT 21 961 21 965 mm 21 953 mm 0 8646 0 8648 in 0 8643 in CONNECTING ROD SMALL END TO PISTON PIN CLEARANCE STANDARD SERVICE LIMIT 0 005 0 015 mm 0 02 mm 0 0002 0 0006 in 0 001 in STANDARD SERVICE LIMIT 0 005 0 002 mm 0 0...

Page 452: ... 0002 in Max 0 010 mm 0 0004 in STANDARD SERVICE LIMIT 0 005 mm 0 0002 in Max 0 010 mm 0 0004 in 1 ROUNDNESS Measure at the center of the journal 2 ROUNDNESS 3 CYLINDRICITY A B A B 4 CYLINDRICITY Measure at both ends of the journal 1 CRANK PINS 5 NO 1 MAIN JOURNAL 1 NO 2 MAIN JOURNAL 4 NO 3 MAIN JOURNAL 2 NO 4 MAIN JOURNAL 3 NO 5 MAIN JOURNAL STANDARD SERVICE LIMIT No 1 2 4 5 54 984 54 992 mm 2 16...

Page 453: ...PPER MAIN BEARING 2 NO 5 UPPER MAIN BEARING STANDARD SERVICE LIMIT 0 10 0 35 mm 0 45 mm 0 004 0 014 in 0 018 in STANDARD SERVICE LIMIT 0 10 0 35 mm 0 45 mm 0 004 0 014 in 0 018 in If the measurement exceeds the service limit check the thrust washer and the cylinder block thrust surface Replace the thrust washer and recheck If the measurement still exceeds the service limit replace the crankshaft I...

Page 454: ...tion Tighten the connecting rod bolts with care not to turn the crankshaft and connecting rod 4 Reinstall the connecting rod cap and tighten the connecting rod bolts to the specified torque P 13 22 5 Remove the connecting rod cap Measure the pressured width of the plastigauge using the scale printed on the bag of the plastigauge Measure the widest width on the plastigauge NOTICE NOTICE 1 PLASTIGAU...

Page 455: ... width of the plastigauge using the scale printed on the bag of the plastigauge Measure the widest width on the plastigauge NOTICE NOTICE 6 If the measurement exceeds the service limit check the lower block and the cylinder block main bearing I D and the crankshaft main journal O D If they are OK replace with the undersize bearing by referring to the connecting rod bearing selection table P 13 18 ...

Page 456: ...s when viewed from the crankshaft pulley side Connecting rod big end I D 51 mm 2 0 in NOTICE NOTICE 2 Check the crank pin code letters and record them The crank pin code letters are for the No 1 and the subsequent number journals when viewed from the right side of the position shown or from the crankshaft pulley side 3 Select the correct bearing by referring to the crank pin code letter and the co...

Page 457: ...ace Do not determine the bearing simply by referring to the selection table but check the oil clearance If the selection table shows two identification colors use a pair of the bearing of each color for the upper and lower bearings NOTICE 2 IDENTIFICATION COLOR 1 PROJECTION Connecting rod code number 1 or l 2 or ll 3 or lll 4 or llll Bearing identification color A Red Pink Pink Yellow Yellow B Pin...

Page 458: ... 2 3 in NOTICE NOTICE 2 Check the crankshaft main journal code numbers and record them The crankshaft main journal code numbers are for the No 1 and the subsequent number journals when viewed from the right side of the position shown or from the crankshaft pulley side 3 Select the correct bearing by referring to the cylinder block I D code letter or number and the crankshaft main journal code numb...

Page 459: ...by referring to the selection table but check the oil clearance If the selection table shows two identification colors use a pair of the bearing of each color for the upper and lower bearings NOTICE 2 IDENTIFICATION COLOR 1 PROJECTION Selection table Main bearing center thickness 2 0 mm 0 08 in Cylinder block I D code letter or number 1 or A or l 2 or B or ll 3 or C or lll 4 or D or llll Bearing i...

Page 460: ...ston pin Install the piston pin so that the mark on the piston head points to the model mark on the connecting rod 4 Install the piston pin clip on the opposite side from where the piston pin clip was installed in step 3 Take care not to let the piston pin clip jump out of position 5 Install the connecting rod bearing on the connecting rod by aligning the projection on the bearing with the concave...

Page 461: ...t the lug of the side rail top side sets in the positioning groove securely NOTICE 7 After installing the piston rings check for smooth movement of each ring Except side rail top side 8 Stagger the piston ring end gaps as shown Do not align with the piston pin and avoid the direction that makes a right angle with the piston pin NOTICE 1 DIMENSIONS OF PISTON RING A B 2 TOP RING A 3 1 mm B 1 2 mm SE...

Page 462: ... seat of the oil jet bolts 4 Install the oil jet body on each of the No 1 and No 2 cylinder and tighten the oil jet bolts to the specified torque TORQUE 16 N m 1 6 kgf m 12 lbf ft 5 Apply engine oil to the new 6 5 x 1 5 mm O ring and install it on the oil jet orifice Install the oil jet orifice on the cylinder block 1 MARK 3 PISTON RING COMPRESSOR Commercially available 3 OIL JET ORIFICE 2 6 5 x 1...

Page 463: ...ft on the cylinder block while aligning it with the No 2 and No 3 connecting rods Install the crankshaft with care not to damage the journals NOTICE 9 Install the connecting rod bearing on the connecting rod cap aligning the projection on the connecting rod bearing with the concave in the connecting rod cap 10 Install the two dowel pins on the connecting rod cap 6 UPPER MAIN BEARING 5 2 UPPER MAIN...

Page 464: ... turn the crankshaft to bring the piston at the bottom dead center NOTICE 12 Apply engine oil to the thrust washers and install them on the cylinder block No 4 journal Install the thrust washers with the grooved side toward the crankshaft NOTICE 13 Install the lower main bearings on the cylinder block aligning the projection on the lower main bearing with the concave in the lower block 14 Apply en...

Page 465: ... block Assemble the lower block within 5 minutes after applying the liquid gasket If it has been left for 5 minutes or longer remove the old liquid gasket and apply the liquid gasket again Do not pour the engine oil in the oil tank at least 30 minutes after assembly NOTICE 17 Install the eleven dowel pins and the lower block on the cylinder block 1 Apply a bead of liquid gasket 2 13 x 14 mm DOWEL ...

Page 466: ...fter tightening to the specified torque tighten the bolt washers to an additional 56 in the numbered order TORQUE 29 N m 3 0 kgf m 22 lbf ft 56 20 Apply engine oil to the threads and seating face of both the 8 x 50 mm flange bolts and the 8 x 35 mm flange bolts 21 Loosely tighten the four 8 x 50 mm flange bolts and ten 8 x 35 mm flange bolts on the lower block Tighten them to the specified torque ...

Page 467: ...river 07749 0010000 Oil seal driver attachment 96 07ZAD PNA0100 Drive in the oil seal with the part number on the oil seal toward out 24 Install the following pars Crankcase balancer case assembly P 12 8 Flywheel P 11 14 Oil pump P 11 11 Engine assembly P 7 6 Cylinder head assembly P 10 32 L R engine under covers P 4 14 Engine cover P 4 2 NOTICE 5 80 x 98 x 10 mm OIL SEAL 4 CRANKSHAFT 3 OIL SEAL I...

Page 468: ...BLY 2 13 PROPELLER SHAFT PROPELLER SHAFT HOLDER 2 14 VERTICAL SHAFT BEVEL GEAR 2 15 SHIM SELECTION 2 16 SHIM POSITION 2 17 BACKLASH ADJUSTMENT 2 18 ANODE METAL WATER SCREEN 19 EXTENSION CASE LOWER RUBBER MOUNT 20 OIL CASE 14 PROPELLER GEAR CASE EXTENSION CASE OIL CASE 1 LC XC LD and XD types 2 XCC LCD and XCD types 83 N m 8 5 kgf m 61 lbf ft 39 N m 4 0 kgf m 29 lbf ft 34 N m 3 5 kgf m 25 lbf ft 1 ...

Page 469: ...CASTLE NUT INSTALLATION TORQUE 1 N m 0 1 kgf m 0 7 lbf ft If the split pin cannot be set by tightening to the specified torque tighten the castle nut additionally until the split pin can be set MAX TORQUE 44 N m 4 5 kgf m 33 lbf ft 2 3 BLADE PROPELLER 4 PROPELLER WASHER 5 PROPELLER THRUST WASHER INSTALLATION Install the propeller thrust washer as shown 3 1 3 mm SPLIT PIN 5 2 PROPELLER SIDE 5 1 GEA...

Page 470: ...r Remove the trim tab from the gear case assembly 5 Remove the seven 10 x 40 mm hex bolts and the seven 10 mm washers then remove the gear case assembly from the outboard motor Remove the two dowel pins 6 After removing the gear case assembly lower the outboard motor to the lowermost position 2 SPEED SENSOR TUBE C 1 SPEED SENSOR TUBE B 2 10 x 32 mm HEX BOLT 3 10 x 40 mm HEX BOLT 7 1 6 x 10 mm DOWE...

Page 471: ...aft A b COMPONENTS DRAWING 2 SHIFT ROD A 1 SHIFT ROD A 9 VERTICAL SHAFT 1 SHIFT SHAFT A 5 10 x 32 mm HEX BOLT 4 TRIM TAB 6 10 mm WASHER 2 10 mm WASHER 7 7 GEAR CASE ASSEMBLY 3 10 x 40 mm HEX BOLT 7 34 N m 3 5 kgf m 25 lbf ft 8 6 x 10 mm DOWEL PIN 2 ...

Page 472: ... equivalent material and turn the shift rod right and left with a wrench until the cutout faces toward the specified direction 3 SHIFT ROD 2 SHIFT ROD 1 CUTOUT 1 SHOP TOWEL 2 CRUISING DIRECTION 1 SHIFT SHAFT A 5 SHIFT ROD A 2 PROJECTION 3 CUTOUT 4 CRUISING DIRECTION 4 CRUISING DIRECTION 4 Tilt up the outboard motor to the uppermost position 5 Apply grease to the spline of the shift rod A 6 Install...

Page 473: ...ers and the seven 10 x 40 mm hex bolts 10 Connect the speed sensor tube B and the speed sensor tube C 11 Lower the outboard motor to the lowermost position and tighten the seven 10 x 40 mm hex bolts to the specified torque TORQUE 34 N m 3 5 kgf m 25 lbf ft 12 Position the trim tab on the gear case assembly 13 Install the trim tab on the gear case assembly aligning the mark on the trim tab with the...

Page 474: ...ove the four distance collars from the impeller housing 4 Remove the woodruff key from the vertical shaft 5 Remove the impeller cover impeller gasket two dowel pins gear case grommet and the rubber setting plate Replace the impeller gasket with a new one on assembly NOTICE 8 IMPELLER HOUSING 1 WATER TUBE SEAL RING 2 8 x 40 mm HEX BOLT 4 4 DISTANCE COLLAR 4 5 WOODRUFF KEY 7 VERTICAL SHAFT 1 IMPELLE...

Page 475: ... mm O ring from the water seal housing Replace the O ring with a new one on assembly 10 Before removing the 23 x 36 x 6 mm water seal check the water seal lip for cut Replace if necessary 11 Remove the two 23 x 36 x 6 mm water seals from the water seal housing using a commercially available oil seal remover Replace the water seals with the new ones on assembly 1 IMPELLER HOUSING 3 PUMP IMPELLER 2 ...

Page 476: ...1 x 6 mm water seals from the shift rod holder using a commercially available oil seal remover 16 Remove the 55 6 x 3 5 mm O ring from the shift rod holder Replace the 12 x 21 x 6 mm water seals with the new ones on assembly Replace the 55 6 x 3 5 mm O ring with a new one on assembly NOTICE 3 6 x 12 mm HEX BOLT 4 PIVOT WASHER 1 SHIFT ROD HOLDER 2 SHIFT ROD HOLDER 2 SHIFT ROD ASSEMBLY 1 12 x 21 x 6...

Page 477: ...R SEAL HOUSING 15 58 5 x 3 5 mm O RING 14 23 x 36 x 6 mm WATER SEAL 2 1 IMPELLER HOUSING 2 WATER TUBE SEAL RING 5 DISTANCE COLLAR 4 9 WOODRUFF KEY 12 VERTICAL SHAFT 10 IMPELLER COVER 11 IMPELLER GASKET 13 6 x 10 mm DOWEL PIN 2 4 8 mm WASHER 4 3 8 x 40 mm HEX BOLT 4 19 7 N m 2 0 kgf m 14 lbf ft ...

Page 478: ... SPEED SENSOR TUBE C 8 SENSOR NIPPLE 10 TUBE JOINT 7 6 x 12 mm HEX BOLT 6 PIVOT WASHER 2 SHIFT ROD HOLDER 1 12 x 21 x 6 mm WATER SEAL 2 15 55 6 x 3 5 mm O RING 11 SHIFT ROD 14 SHIFT ROD SPRING 13 12 mm WASHER 12 10 mm E RING 5 WIRE BAND 2 Do not reuse ...

Page 479: ...lation TOOLS Driver 07749 0010000 Oil seal driver attachment 21 mm 07947 ZV00100 3 After installing the water seals apply grease to the water seal lips 4 Position the 10 mm E ring 12 mm washer and the shift rod spring on the shift rod 5 OIL SEAL DRIVER ATTACHMENT 21 mm 07947 ZV00100 4 DRIVER 07749 0010000 6 SHIFT ROD HOLDER 2 12 x 21 x 6 mm WATER SEALS 1 Water seal installation direction 3 Apply g...

Page 480: ...erence of the new 55 6 x 3 5 mm O ring and install it on the shift rod holder 7 Install the shift rod holder aligning the projection with the concave in the gear case and tighten with the pivot washer and the 6 x 12 mm hex bolt After installation check that the cutout of the shift rod spline faces in the cruising direction 1 55 6 x 3 5 mm O RING 2 SHIFT ROD HOLDER 1 SHIFT ROD HOLDER 4 PIVOT WASHER...

Page 481: ...ing the water seals apply grease to the water seal lips 11 Apply grease to the circumference of the new 58 5 x 3 5 mm O ring and position it on the water seal housing 12 Install the water seal housing so that the concave faces in the cruising direction and tighten it with the two 6 x 20 mm flange bolts 4 DRIVER 07749 0010000 5 ATTACHMENT 32 x 35 mm 07746 0010100 1 23 x 36 x 6 mm WATER SEALS 3 58 5...

Page 482: ...ing Be sure that the part A of the water pump liner is in alignment with the part B of the impeller housing too 15 Apply grease to the circumference of the new water pump O ring and install it on the impeller housing 16 Install the rubber setting plate gear case grommet two dowel pins new impeller gasket and the impeller cover 4 WATER PUMP LINER 2 WOODRUFF KEY INSTALLATION GROOVE 2 WOODRUFF KEY IN...

Page 483: ...ance collars on the impeller housing and tighten the four 8 mm washers and the four 8 x 40 mm hex bolts to the specified torque TORQUE 19 7 N m 2 0 kgf m 14 lbf ft 19 Apply grease to the inner wall of the water tube seal ring Install the water tube seal ring aligning the projection with the hole in the housing 20 Install the speed sensor tube C 21 Install the following parts Gear case assembly P 1...

Page 484: ...hers and the two 10 x 40 mm flange bolts 2 Insert a screwdriver or equivalent tool into the recess in the propeller shaft holder and remove the propeller shaft holder assembly from the gear case Installation is the reverse order of removal 3 10 mm WASHER 2 2 PROPELLER SHAFT HOLDER ASSEMBLY 2 PROPELLER SHAFT HOLDER ASSEMBLY 1 GEAR CASE ASSEMBLY 1 RECESS 10 x 40 2 34 N m 3 5 kgf m 25 lbf ft ...

Page 485: ... cross pin ring and the 8 x 47 mm shifter pin then remove the clutch shifter 2 Remove the shift slider assembly and the two 7 steel balls from the propeller shaft Take care not to lose the steel balls 3 Remove the 14 mm circlip from the shift slider assembly 3 CROSS PIN RING 1 8 x 47 mm SHIFTER PIN 2 CLUTCH SHIFTER 3 7 STEEL BALL 2 2 SHIFT SLIDER ASSEMBLY 1 SHIFT SLIDER ASSEMBLY 2 14 mm CIRCLIP 1 ...

Page 486: ... springs and the 9 steel balls pop out of the shift slider during removal of the shift plate NOTICE 6 Remove the reverse bevel gear bearing assembly and the propeller shaft from the propeller shaft holder using the hydraulic press as shown 2 SHIFT SLIDER ASSEMBLY 1 SHIFT SLIDER 3 SHIFT PLATE 4 SHIFT SPRINGS 4 REVERSE BEVEL GEAR BEARING ASSEMBLY 2 PROPELLER SHAFT 1 PROPELLER SHAFT HOLDER 3 HYDRAULI...

Page 487: ... washer and the 105 x 3 1 mm O ring from the propeller shaft holder Replace the O ring with a new one on assembly 12 Before removing the 30 x 45 x 7 mm water seals check the water seal lips for cut and other damage Replace the water seals if necessary 13 Remove the two 30 x 45 x 7 mm water seals from the propeller shaft holder using a commercially available oil seal remover Replace the water seals...

Page 488: ... 3710100 Bearing remover 30 mm 07936 8890300 b INSPECTION CLUTCH SHIFTER Check the clutch part of the forward and reverse sides for wear and damage PROPELLER SHAFT O D 3 BEARING REMOVER 30 mm 07936 8890300 1 REMOVER WEIGHT 07741 0010201 2 REMOVER HANDLE 07936 3710100 4 PROPELLER SHAFT HOLDER 1 CLUTCH PARTS 1 AT FORWARD BEVEL GEAR 2 AT NEEDLE BEARING STANDARD SERVICE LIMIT At forward 24 987 25 000 ...

Page 489: ...ING 13 THRUST BEARING 14 THRUST BEARING WASHER 18 30 x 45 x 7 mm WATER SEAL 2 15 105 x 3 1 mm O RING 4 SHIFT SLIDER 10 SHIFT PLATE 9 SHIFT SPRING 2 16 PROPELLER SHAFT HOLDER 8 9 STEEL BALLS 6 3 x 12 8 mm ROLLER 3 CROSS PIN RING 2 8 x 47 mm SHIFTER PIN 1 CLUTCH SHIFTER 5 7 STEEL BALL 2 7 14 mm CIRCLIP 19 PROPELLER SHAFT ...

Page 490: ...30 x 45 x 7 mm water seals one by one into the propeller shaft holder using the special tool Note the installation direction of the water seals Apply grease to the water seal mating surfaces before installation TOOL Oil seal driver 07947 SB00100 5 After installation of the water seals apply grease to the water seal lips 1 ATTACHMENT 62 x 68 mm 07746 0010500 2 OUTER DRIVER ATTACHMENT 30 x 37 070PD ...

Page 491: ...er thrust bearing propeller shaft and the reverse bevel gear bearing assembly in this order quickly on the propeller shaft holder Note to install the thrust bearing water with the chamfered side toward the holder Do not heat the oil above 90 C 194 F The entire holder becomes hot Be sure to wear the gloves during the operation 13 Apply grease to the circumference of the new 105 x 3 1 mm O ring and ...

Page 492: ...embly into the propeller shaft with care not to allow the 7 steel balls to pop out NOTICE 17 With the F mark on the clutch shifter toward the forward bevel gear i e toward front assemble the clutch shifter with the propeller shaft while aligning the 8 x 47 mm shifter pin installation hole with the long hole in the propeller shaft 3 SHIFT SPRINGS 4 SHIFT PLATE 1 SHIFT SLIDER 2 3 x 12 8 mm ROLLER 6 ...

Page 493: ...de If it is at the reverse bevel gear installation side pull up the shift slider assembly slowly Be sure that the 7 steel balls cannot be checked through the gap between the propeller shaft and shift slider If the steel balls can be checked push in the shift slider assembly slowly again 21 Install the following parts Propeller shaft holder assembly P 14 17 Water pump shift rod P 14 12 Gear case as...

Page 494: ...916 MB00002 5 Remove the vertical shaft assembly Take care not to drop the needle bearing roller when removing the vertical shaft assembly NOTICE 6 Check the needle bearing for abnormal sound and play If there is abnormal sound and play replace the roller and the outer race as a set 7 Remove the needle bearing roller 8 Check the taper bearing inner race of the forward bevel gear taper bearing asse...

Page 495: ...abnormality before removing it Replace the inner race and the outer race as a set if necessary 15 Set a commercially available universal bearing puller on the taper roller bearing inner race and install the vertical shaft on the hydraulic press with the crankshaft installation side toward up 16 Remove the taper roller bearing from the vertical shaft using the hydraulic press 17 Remove the pinion g...

Page 496: ...00 Pilot 35 mm 07746 0040800 20 Remove the needle bearing outer race from the gear case using the special tools Remove the needle bearing outer race with care not to damage the gear case Replace the needle bearing outer race and the roller as a set on assembly NOTICE b INSPECTION VERTICAL SHAFT O D 1 DRIVER HANDLE 15 x 280 mm 07949 3710001 2 BEARING DRIVER ATTACHMENT 37 mm 07ZMD MBW0200 5 PILOT 35...

Page 497: ... RACE 3 30 x 62 x 40 mm TAPER ROLLER BEARING INNER RACE 1 VERTICAL SHAFT 15 GEAR CASE 10 PINION GEAR 9 NEEDLE BEARING ROLLER 6 FORWARD BEVEL GEAR 14 1 Replace the inner race and the outer race as a set after removing the taper bearing inner race from the forward bevel gear 7 50 x 90 x 28 mm TAPER BEARING INNER RACE 2 64 mm LOCK NUT 11 PINION GEAR NUT 142 N m 14 5 kgf m 105 lbf ft 1 c COMPONENTS DR...

Page 498: ...70GD 0010100 Taper vearing installer attachment 070PF ZY60100 Install the taper bearing outer race with the larger diameter side toward the forward bevel gear 7 Install the forward bevel gear taper bearing assembly in the gear case NOTICE 8 Install the pinion gear on the vertical shaft and loosely tighten the pinion gear nut by hand 9 Apply gear oil to the inner wall of the inner race roller and t...

Page 499: ...oil slinger on the vertical shaft aligning the projection on the inside of the oil slinger with the concave of the pinion gear installation side of the vertical shaft 15 Attach the special tool to the new needle bearing as shown Install the needle bearing with the stamped side of the needle bearing outer race toward the special tool TOOL Oil seal driver attachment 27 5 x 44 mm 07948 9540000 7 DRIV...

Page 500: ...ring roller 18 Install the vertical shaft assembly taking care not to bring the needle bearing roller out of position 19 Apply the thread locking agent to the threads and seat of the 64 mm lock nut and tighten the lock nut using the special tool TOOL Lock nut wrench 30 64 mm 07916 MB00002 TORQUE 123 N m 12 5 kgf m 90 lbf ft 4 OIL SEAL DRIVER ATTACHMENT 27 5 x 44 mm 07948 9540000 1 SHAFT INSTALLER ...

Page 501: ...il to the threads and seat of the pinion gear nut 24 Install the pinion gear on the vertical shaft Holding the special tool in the position tighten the pinion gear nut to the specified torque TORQUE 142 N m 14 5 kgf m 105 lbf ft Check that the forward bevel gear taper bearing assembly is set properly 25 Install the following parts Propeller shaft holder assembly P 14 17 Water pump shift rod P 14 1...

Page 502: ...adapter 110 mm 070PJ ZY30100 4 Holding the special tool with the side of the stamped tool number facing the opposite side from the pinion gear be sure that the tool of the pinion gear nut side is not set on the nut Tighten the bolts by hand while pushing both tools toward the pinion gear side Do not tighten the bolts with a tool There must be no wobbling in the special tool It must securely set on...

Page 503: ...cord it 8 Assemble the outer race and the inner race of the 30 x 62 x 40 mm taper roller bearing and turn the outer race two or three turns 9 Measure the bearing height from the outer race end to the inner race end as shown and record the measurement 10 Measure the height of the taper roller bearing outer race and record it 1 DEPTH GAUGE Commercially available 2 PINION GEAR 1 OUTER RACE 1 OUTER RA...

Page 504: ...d in step 11 and the following formula Formula Vertical shaft length distance D Gap distance E 147 2 Calculation value Example When vertical shaft length distance D is 141 8 mm 5 58 in And gap distance E is 5 2 mm 0 20 in 141 8 5 2 147 2 0 20 Therefore the calculation value is 0 20 mm 0 008 in 13 Cross reference the calculation value and the engagement mark located on the trim tab installation par...

Page 505: ... 0 45 0 018 0 50 0 020 0 55 0 022 0 60 0 024 0 65 0 026 0 70 0 028 0 75 0 030 A 0 40 0 0157 0 45 0 018 0 50 0 020 0 55 0 022 0 60 0 024 0 65 0 026 0 70 0 028 3 Unit mm in 2 Calculation value 0 05 0 002 0 0 000 0 05 0 002 0 10 0 004 0 15 0 006 0 20 0 008 0 25 0 010 0 0 000 0 05 0 002 0 10 0 004 0 15 0 006 0 20 0 008 0 25 0 010 0 31 0 0122 F 0 65 0 026 0 70 0 028 0 75 0 030 0 80 0 031 0 85 0 033 0 9...

Page 506: ...t mark located on the trim tab installation part of the gear case and select the shim of the appropriate thickness from the shim selection table accordingly Shim type table 1 OUTER RACE 2 INNER RACE 1 GEAR CASE 2 EMGAGEMENT MARK 1 Shim type 2 Thickness 3 Forward bevel gear shim A 0 10 mm 0 004 in 4 Forward bevel gear shim B 0 15 mm 0 006 in 5 Forward bevel gear shim C 0 30 mm 0 012 in 6 Forward be...

Page 507: ... x 62 x 40 mm TAPER ROLLER BEARING OUTER RACE 1 30 x 62 x 40 mm TAPER ROLLER BEARING INNER RACE 9 VERTICAL SHAFT 8 PINION GEAR 5 FORWARD BEVEL GEAR 7 PINION GEAR NUT 142 N m 14 5 kgf m 105 lbf ft 3 FORWARD BEVEL GEAR SHIM SELECTION P 14 39 ADJUSTMENT P 14 41 10 PINION GEAR SHIM SELECTION P 14 35 6 REVERSE BEVEL GEAR ...

Page 508: ...ure the backlash at the four points by turning the vertical shaft 90 in the same manner Do not turn the propeller shaft when turning the vertical shaft 4 Obtain the forward bevel gear backlash using the dial indicator runout and the following formula Formula Dial indicator runout 0 86 Backlash Example When dial indicator runout is 0 195 mm 0 0077 in 0 195 0 86 0 23 Therefore the backlash is 0 23 m...

Page 509: ...m washer Remove the gear case cover from the gear case assembly 5 Remove the seven 10 x 40 mm hex bolts and the seven 10 mm washers then remove the gear case assembly from the outboard motor 6 After removing the gear case assembly lower the outboard motor to the lowermost position 2 10 x 32 mm HEX BOLT 3 10 mm WASHER 1 GEAR CASE COVER 2 SPEED SENSOR TUBE C 1 SPEED SENSOR TUBE B 3 10 x 40 mm HEX BO...

Page 510: ... A 2 SHIFT ROD A 1 SHIFT SHAFT A b COMPONENTS DRAWING 1 SHIFT ROD A 9 VERTICAL SHAFT 5 10 x 32 mm HEX BOLT 6 10 mm WASHER 2 10 mm WASHER 7 7 GEAR CASE ASSEMBLY 3 10 x 40 mm HEX BOLT 7 8 6 x 10 mm DOWEL PIN 2 4 GEAR CASE COVER 34 N m 3 5 kgf m 25 lbf ft ...

Page 511: ... equivalent material and turn the shift rod right and left with a wrench until the cutout faces toward the specified direction 3 SHIFT ROD 2 SHIFT ROD 1 CUTOUT 1 SHOP TOWEL 2 CRUISING DIRECTION 1 SHIFT SHAFT A 5 SHIFT ROD A 2 PROJECTION 3 CUTOUT 4 CRUISING DIRECTION 4 CRUISING DIRECTION 4 Tilt up the outboard motor to the uppermost position 5 Apply grease to the spline of the shift rod A 6 Install...

Page 512: ...hers and the seven 10 x 40 mm hex bolts 10 Connect the speed sensor tube B and the speed sensor tube C 11 Lower the outboard motor to the lowermost position and tighten the seven 10 x 40 mm hex bolts to the specified torque TORQUE 34 N m 3 5 kgf m 25 lbf ft 12 Position the gear case cover on the gear case assembly 13 Install the gear case cover aligning the mark on the gear case cover with the mar...

Page 513: ...move the four distance collars from the impeller housing 4 Remove the woodruff key from the vertical shaft 5 Remove the impeller cover impeller gasket two dowel pins gear case grommet and the rubber setting plate Replace the impeller gasket with a new one on assembly NOTICE 1 IMPELLER COVER 5 IMPELLER GASKET 4 6 x 10 mm DOWEL PIN 2 2 GEAR CASE GROMMET 3 RUBBER SETTING PLATE 8 IMPELLER HOUSING 1 WA...

Page 514: ...5 mm O ring from the water seal housing Replace the O ring with a new one on assembly 10 Before removing the 23 x 36 x 6 mm water seal check the water seal lip for cut Replace if necessary 11 Remove the two 23 x 36 x 6 mm water seals from the water seal housing using a commercially available oil seal remover Replace the water seals with the new ones on assembly 1 IMPELLER HOUSING 3 PUMP IMPELLER 2...

Page 515: ...21 x 6 mm water seals from the shift rod holder using a commercially available oil seal remover 16 Remove the 55 6 x 3 5 mm O ring from the shift rod holder Replace the 12 x 21 x 6 mm water seals with the new ones on assembly Replace the 55 6 x 3 5 mm O ring with a new one on assembly NOTICE 2 SHIFT ROD HOLDER 1 12 x 21 x 6 mm WATER SEAL 3 55 6 x 3 5 mm O RING 4 SHIFT ROD 2 SHIFT ROD SPRING 3 12 m...

Page 516: ...R SEAL HOUSING 15 58 5 x 3 5 mm O RING 14 23 x 36 x 6 mm WATER SEAL 2 1 IMPELLER HOUSING 2 WATER TUBE SEAL RING 5 DISTANCE COLLAR 4 9 WOODRUFF KEY 12 VERTICAL SHAFT 10 IMPELLER COVER 11 IMPELLER GASKET 13 6 x 10 mm DOWEL PIN 2 4 8 mm WASHER 4 3 8 x 40 mm HEX BOLT 4 19 7 N m 2 0 kgf m 14 lbf ft ...

Page 517: ... SPEED SENSOR TUBE C 8 SENSOR NIPPLE 10 TUBE JOINT 7 6 x 12 mm HEX BOLT 6 PIVOT WASHER 2 SHIFT ROD HOLDER 1 12 x 21 x 6 mm WATER SEAL 2 15 55 6 x 3 5 mm O RING 11 SHIFT ROD 14 SHIFT ROD SPRING 13 12 mm WASHER 12 10 mm E RING 5 WIRE BAND 2 Do not reuse ...

Page 518: ...nstallation TOOLS Driver 07749 0010000 Oil seal driver attachment 21 mm 07947 ZV00100 3 After installing the water seals apply grease to the water seal lips 4 Position the 10 mm E ring 12 mm washer and the shift rod spring on the shift rod 4 SHIFT ROD 2 SHIFT ROD SPRING 3 12 mm WASHER 1 10 mm E RING 5 OIL SEAL DRIVER ATTACHMENT 21 mm 07947 ZV00100 4 DRIVER 07749 0010000 6 SHIFT ROD HOLDER 2 12 x 2...

Page 519: ...ference of the new 55 6 x 3 5 mm O ring and install it on the shift rod holder 7 Install the shift rod holder aligning the projection with the concave in the gear case and tighten it with the pivot washer and the 6 x 12 mm hex bolt After installation check that the cutout of the shift rod spline faces in the cruising direction 1 55 6 x 3 5 mm O RING 2 SHIFT ROD HOLDR 3 SHIFT ROD 5 CAM 6 GROOVE IN ...

Page 520: ...stalling the water seals apply grease to the water seal lips 11 Apply grease to the circumference of the new 58 5 x 3 5 mm O ring and position it on the water seal housing 12 Install the water seal housing so that the concave faces in the cruising direction and tighten it with the two 6 x 20 mm flange bolts 4 DRIVER 07749 0010000 5 ATTACHMENT 32 x 35 mm 07746 0010100 1 23 x 36 x 6 mm WATER SEALS 6...

Page 521: ...liner with the two grooves inside the impeller housing 15 Be sure that the part A of the water pump liner is in alignment with the part B of the impeller housing too 16 Install the rubber setting plate gear case grommet two dowel pins new impeller gasket and the impeller cover 6 WATER PUMP LINER 4 RUBBER SETTING PLATE 3 GEAR CASE GROMMET 5 6 x 10 mm DOWEL PIN 2 1 IMPELLER GASKET 2 IMPELLER COVER 5...

Page 522: ...nd tighten the four 8 mm washers and the four 8 x 40 mm hex bolts to the specified torque TORQUE 19 7 N m 2 0 kgf m 14 lbf ft 19 Apply grease to the inner wall of the water tube seal ring Install the water tube seal ring aligning the projection with the hole in the housing 20 Install the speed sensor tube C assembly 5 x 270 mm tube 21 Install the following parts Gear case assembly P 14 44 Propelle...

Page 523: ...shers and the two 10 x 40 mm flange bolts 2 Insert a screwdriver or equivalent tool into the recess in the propeller shaft holder and remove the propeller shaft holder assembly from the gear case Installation is the reverse order of removal 3 10 mm WASHER 2 2 PROPELLER SHAFT HOLDER ASSEMBLY 2 PROPELLER SHAFT HOLDER ASSEMBLY 1 GEAR CASE ASSEMBLY 1 RECESSE 10 x 40 2 34 N m 3 5 kgf m 25 lbf ft ...

Page 524: ...he cross pin ring and the 8 x 47 mm shifter pin then remove the clutch shifter 2 Remove the shift slider assembly and the two 7 steel balls from the propeller shaft Take care not to lose the steel balls 3 Remove the 14 mm circlip from the shift slider assembly 3 CROSS PIN RING 1 8 x 47 mm SHIFTER PIN 2 CLUTCH SHIFTER 3 7 STEEL BALL 2 2 SHIFT SLIDER ASSEMBLY 1 SHIFT SLIDER ASSEMBY 2 14 mm CIRCLIP 1...

Page 525: ...9 steel balls Take care not to let the shift springs and the 9 steel balls pop out of the shift slider during removal of the shift plate NOTICE 6 Prepare the fixing tool of the dimensions shown 300 mm 11 8 in 60 mm 2 4 in 30 mm 1 2 in 69 5 mm 2 74 in 69 5 mm 2 74 in ø35 1 4 in ø10 0 4 in ø10 0 4 in 2 SHIFT SLIDER ASSEMBLY 1 SHIFT SLIDER 3 SHIFT PLATE 4 SHIFT SPRINGS 2 9 STEEL BALLS 1 3 x 12 8 mm R...

Page 526: ...play If there is any abnormal sound or play in the inner race replace the inner race and the outer race as a set 12 Attach a commercially available universal bearing puller between the bearing holder and the forward bevel gear 13 Remove the forward bevel gear from the taper bearing inner race using the special tools and the hydraulic press TOOLS Driver 07749 0010000 Attachment 27 2 07747 0010300 P...

Page 527: ... holder Replace the shim with a new one on assembly Replace the 105 x 3 1 mm O ring with a new one on assembly NOTICE 20 Before removing the 30 x 45 x 7 mm water seals check the water seal lips for cut and replace if necessary 21 Remove the two 30 x 45 x 7 mm water seals from the propeller shaft holder using a commercially available oil seal remover Replace the water seals with the new ones on ass...

Page 528: ...0100 Bearing remover 30 mm 07936 8890300 b INSPECTION CLUTCH SHIFTER Check the clutch part of the forward and reverse sides for wear and damage PROPELLER SHAFT O D 1 CLUTCH PARTS 1 AT REVERSE BEVEL GEAR 2 AT NEEDLE BEARING 3 BEARING REMOVER 30 mm 07936 8890300 1 REMOVER WEIGHT 07741 0010201 2 REMOVER HANDLE 07936 3710100 4 PROPELLER SHAFT HOLDER STANDARD SERVICE LIMIT At reverse 24 987 25 000 mm 2...

Page 529: ...T HOLDER 24 PROPELLER SHAFT 15 50 x 90 x 28 mm TAPER BEARING OUTER RACE 18 THRUST SHIM 1 FORWARD BEVEL GEAR 23 50 x 90 x 28 mm TAPER BEARING INNER RACE 14 BEARING HOLDER 191 N m 19 5 kgf m 141 lbf ft 12 FORWARD BEVEL GEAR SHIM 5 SHIFT SLIDER 11 SHIFT PLATE 10 SHIFT SPRING 2 9 9 STEEL BALLS 7 3 x 12 8 mm ROLLER 4 CROSS PIN RING 3 8 x 47 mm SHIFTER PIN 2 CLUTCH SHIFTER 6 7 STEEL BALL 2 8 14 mm CIRCL...

Page 530: ... the 30 x 45 x 7 mm water seals one by one into the propeller shaft holder using the special tool Note the installation direction of the water seals Apply grease to the water seal mating surfaces before installation TOOL Oil seal driver 07947 SB00100 5 After installation of the water seals apply grease to the water seal lips 1 ATTACHMENT 62 x 68 mm 07746 0010500 2 OUTER DRIVER ATTACHMENT 30 x 37 0...

Page 531: ...der Install the taper bearing outer race with the smaller diameter side toward the shim NOTICE 14 Install the taper bearing outer race on the bearing holder using the special tools and the hydraulic press as shown TOOLS Driver 07749 0010000 Taper bearing inataller attachment 070PF ZY60100 3 THRUST BEARING WASHER 5 105 x 3 1 mm O RING 2 THRUST BEARING WASHER 4 PROPELLER SHAFT HOLDER 1 PROPELLER SHA...

Page 532: ...opeller shaft Loosely tighten the bearing holder assembly by hands against the propeller shaft holder 21 Attach the fixing tool that had been used during propeller shaft propeller shaft holder removal on the propeller shaft holder assembly and secure with the bolt 22 Tighten the bearing holder to the specified torque using the special tool as shown TOOL Pin spanner wrench 110 mm 07WAA S1G0100 TORQ...

Page 533: ...y into the propeller shaft with care not to allow the 7 steel balls to pop out NOTICE 26 With the F mark on the clutch shifter toward the reverse bevel gear i e toward front assemble the clutch shifter with the propeller shaft while aligning the 8 x 47 mm shifter pin installation hole with the long hole in the propeller shaft 3 SHIFT SPRINGS 4 SHIFT PLATE 1 SHIFT SLIDER 2 3 x 12 8 mm ROLLER 6 14 m...

Page 534: ...e If it is at the forward bevel gear installation side pull up the shift slider assembly slowly Be sure that the 7 steel balls cannot be checked through the gap between the propeller shaft and shift slider If the steel balls can be checked push in the shift slider assembly slowly again 30 Install the following parts Propeller shaft holder assembly P 14 56 Water pump shift rod P 14 51 Gear case ass...

Page 535: ...ace a shop towel or equivalent material as shown to protect the gear case 3 Holding the special tool remove the pinion gear nut and the pinion gear 4 Remove the 64 mm lock nut using the special tool as shown TOOL Lock nut wrench 30 64 mm 07916 MB00002 5 Remove the vertical shaft assembly Take care not to drop the needle bearing roller when removing the vertical shaft assembly NOTICE 2 VERTICAL SHA...

Page 536: ...rse bevel gear using the special tools with the new puller jaws replaced in step 8 as shown TOOLS Remover weight 07741 0010201 Remover handle 07936 3710100 Bearing race puller 070PC ZY3A100 Puller jaws 25 mm 07WPC ZW50100 1 NEEDLED BEARING ROLLER 1 PULLER JAWS 25 mm 07WPC ZW50100 Replacement tool 2 BEARING RACE PULLER 070PC ZY3A100 4 PULLER JAWS 25 mm 07WPC ZW50100 2 BEARING RACE PULLER 070PC ZY3A...

Page 537: ...ng for noise play and other abnormality before removing it Replace the inner race and the outer race as a set if necessary 15 Position a commercially available universal bearing puller on the taper roller bearing inner race and position the vertical shaft on the hydraulic press with the crankshaft installation side toward up 16 Remove the taper roller bearing from the vertical shaft using the hydr...

Page 538: ... the needle bearing outer race from the gear case using the special tools Remove the needle bearing outer race with care not to damage the gear case Replace the needle bearing outer race and the roller as a set on assembly NOTICE 1 DRIVER HANDLE 15 x 280 mm 07949 3710001 2 BEARING DRIVER ATTACHMENT 37 mm 07ZMD MBW0200 5 PILOT 35 mm 07746 0040800 6 NEEDLE BEARING OUTER RACE 4 SHOP TOWEL 3 GEAR CASE...

Page 539: ... x 62 x 40 mm TAPER ROLLER BEARING INNER RACE 3 30 x 62 x 40 mm TAPER ROLLER BEARING INNER RACE 1 VERTICAL SHAFT 13 GEAR CASE 9 PINION GEAR 8 NEEDLE BEARING ROLLER 2 64 mm LOCK NUT 123 N m 12 5 kgf m 90 lbf ft 10 PINION GEAR NUT 142 N m 14 5 kgf m 105 lbf ft 12 REVERSE BEVEL GEAR SHIM 11 50 x 90 x 20 mm RADIAL BALL BEARING 6 REVERSE BEVEL GEAR ...

Page 540: ...tallation side of the gear case becomes hot remove the gear case from the container and install the bevel gear shim and the reverse bevel gear bearing assembly on the gear case quickly Do not heat the oil above 90 C 194 F The entire gear case becomes hot Be sure to wear the gloves during the operation Do not apply the force of 8 829 N 900 kgf 1984 lbf or above during installation NOTICE 1 OIL SEAL...

Page 541: ...ar toward up as shown 11 Install the taper roller bearing on the vertical shaft using the hydraulic press Check that the ends of the special tool are set on the taper roller bearing inner race and the hydraulic press table securely Do not ruin the threads at the end of the vertical shaft pinion gear nut installation part 12 Remove the pinion gear nut and the pinion gear from the vertical shaft NOT...

Page 542: ...gear case using the special tools TOOLS Shaft installer 15 x 370 mm 07VMF KZ30200 Attachment 78 x 90 mm 07GAD SD40101 Oil seal driver attachment 27 5 x 44 mm 07948 9540000 16 After installation check that the bottom surface of the needle bearing is flush with the bottom of the gear case Apply grease to the needle bearing roller 4 OIL SEAL DRIVER ATTACHMENT 27 5 x 44 mm 07948 9540000 1 SHAFT INSTAL...

Page 543: ...Vertical shaft holder 07SPB ZW10200 21 Place a shop towel in the gear case as shown to protect the gear case 22 Apply gear oil to the threads and seat of the pinion gear nut 23 Tighten the pinion gear nut to the specified torque while installing the pinion gear on the vertical shaft and holding the special tool in position TORQUE 142 N m 14 5 kgf m 105 lbf ft Check that the forward bevel gear tape...

Page 544: ...Gauge adapter 110 mm 070PJ ZY30100 4 Holding the special tool with the side of the stamped tool number facing the opposite side from the pinion gear be sure that the tool of the pinion gear nut side is not set on the nut Tighten the bolts by hand while pushing both tools toward the pinion gear side Do not tighten the bolts with a tool There must be no wobbling in the special tool It must securely ...

Page 545: ...cord it 8 Assemble the outer race and the inner race of the 30 x 62 x 40 mm taper roller bearing and turn the outer race two or three turns 9 Measure the bearing height from the outer race end to the inner race end as shown and record the measurement 10 Measure the height of the taper roller bearing outer race and record it 3 GAUGE ADAPTER 110 mm 070PJ ZY30100 1 DEPTH GAUGE Commercially available ...

Page 546: ...d in step 11 and the following formula Formula Vertical shaft length distance D Gap distance E 147 2 Calculation value Example When vertical shaft length distance D is 141 8 mm 5 58 in And gap distance E is 5 2 mm 0 20 in 141 8 5 2 147 2 0 20 Therefore the calculation value is 0 20 mm 0 008 in 13 Cross reference the calculation value and the engagement mark located on the trim tab installation par...

Page 547: ... 0 010 0 30 0 0118 0 35 0 014 0 40 0 0157 A 0 10 0 004 0 15 0 006 0 20 0 008 0 25 0 010 0 30 0 0118 0 35 0 014 3 Unit mm in 3 Unit mm in 2 Calculation value 0 05 0 002 0 0 000 0 05 0 002 0 10 0 004 0 15 0 006 0 20 0 008 0 25 0 010 0 0 000 0 05 0 002 0 10 0 004 0 15 0 006 0 20 0 008 0 25 0 010 0 31 0 0122 F 0 65 0 026 0 70 0 028 0 75 0 030 0 80 0 031 0 85 0 033 0 90 0 035 0 95 0 037 E 0 60 0 024 0 ...

Page 548: ...ce F is 28 05 mm 1 104 in And inner race height distance K is 28 00 mm 1 102 in 28 05 28 00 0 05 Therefore the calculation value is 0 05 mm 0 002 in 5 Check the calculation value and select the shim of the appropriate thickness from the shim selection table accordingly Shim type table 3 Unit mm in 1 50 x 90 x 28 mm TAPER BEARING INNER RACE 1 OUTER RACE 2 INNER RACE 1 Shim type 2 Thickness 3 Forwar...

Page 549: ... gear case and select the shim of the appropriate thickness from the shim selection table accordingly Shim type table 1 GEAR CASE 2 ENGAGEMENT MARK 1 Shim type 2 Thickness 3 Forward bevel gear shim A 0 10 mm 0 004 in 4 Forward bevel gear shim B 0 15 mm 0 006 in 5 Forward bevel gear shim C 0 30 mm 0 012 in 6 Forward bevel gear shim D 0 50 mm 0 020 in Reverse bevel gear shim selection table 2 Calcul...

Page 550: ... K and the following formula Formula Bearing height distance F Inner race height distance K Calculation value Example When bearing height distance F is 28 05 mm 1 104 in And inner race height distance K is 28 00 mm 1 102 in 28 05 28 00 0 05 Therefore the calculation value is 0 05 mm 0 002 in 5 Check the calculation value and the bearing height and select the shim of the appropriate thickness from ...

Page 551: ... P 14 87 4 REVERSE BEVEL GEAR 2 50 x 90 x 20 mm RADIAL BALL BEARING 7 50 x 90 x 28 mm TAPER BEARING OUTER RACE 5 FORWARD BEVEL GEAR 8 50 x 90 x 28 mm TAPER BEARING INNER RACE 14 30 x 62 x 40 mm TAPER ROLLER BEARING OUTER RACE 1 30 x 62 x 40 mm TAPER ROLLER BEARING INNER RACE 12 VERTICAL SHAFT 11 PINION GEAR 10 PINION GEAR NUT 142 N m 14 5 kgf m 105 lbf ft 13 PINION GEAR SHIM SELECTION P 14 77 ...

Page 552: ...sure the backlash at the four points by turning the vertical shaft 90 in the same manner Do not turn the propeller shaft when turning the vertical shaft 4 Obtain the forward bevel gear backlash using the dial indicator runout and the following formula Formula Dial indicator runout 0 86 Backlash Example When dial indicator runout is 0 195 mm 0 0077 in 0 195 0 86 0 23 Therefore the backlash is 0 23 ...

Page 553: ...nner Do not turn the propeller shaft when turning the vertical shaft 5 Obtain the reverse bevel gear backlash using the dial indicator runout and the following formula Formula Dial indicator runout 0 86 Backlash Example When dial indicator runout is 0 195 mm 0 0077 in 0 195 0 86 0 23 Therefore the backlash is 0 23 mm 0 009 in NOTICE 1 BACKLASH INDICATOR ATTACHMENT 07SPK ZW10100 2 BACKLASH INDICATO...

Page 554: ...ng the bolt as shown P 14 59 3 Set the dial indicator perpendicularly so that its tip contacts the end of the propeller shaft 4 Move the propeller shaft up and down and read the runout of the dial indicator It must be within the specified range 2 PROPELLER SHAFT HOLDER ASSEMBLY 3 FIXING TOOL 1 DIAL INDICATOR Standard value 0 2 0 4 mm 0 01 0 02 in 5 If the thrust clearance exceeds the specification...

Page 555: ...TAL 2 INSPECTION Replace the anode metal if it is corroded excessively 4 5 5 x 1 5 mm O RING Do not reuse 4 5 5 x 1 5 mm O RING Do not reuse 5 OIL LEVEL BOLT 3 4 N m 0 35 kgf m 2 5 lbf ft 1 5 x 50 mm OVAL SCREW 1 N m 0 1 kgf m 0 7 lbf ft 9 OIL DRAIN BOLT 3 4 N m 0 35 kgf m 2 5 lbf ft 11 L WATER SCREEN INSPECTION Check for the clogged water through hole before installation 10 GEAR CASE ASSEMBLY 2 6...

Page 556: ...ubber mount and the lower mount collar from the extension case 6 Remove the eight 10 x 40 mm flange bolts and remove the extension case from the outboard motor Remove the two dowel pins Remove the extension case with care not to drop it 7 Remove the under cover seal B and the extension case grommet from the extension case 8 Remove the circlip and then remove the 26 mm washer and the vertical shaft...

Page 557: ... RUBBER MOUNT 2 4 LOWER MOUNT COLLAR 2 13 EXTENSION CASE 12 VERTICAL SHAFT BUSHING 11 26 mm WASHER 9 CIRCLIP 10 XC XCC XD and XCD types only 8 6 x 10 mm DOWEL PIN 2 3 UNDER COVER SEAL B 18 EXTENSION CASE GROMMET 6 12 mm WASHER 4 14 LOWER MOUNT HOUSING 2 15 8 mm WASHER 6 10 x 40 8 39 N m 4 0 kgf m 29 lbf ft 1 12 x 225 mm HEX BOLT 2 6 x 12 2 WATER TUBE SETTING PLATE 1 WATER TUBE GROMMET 3 WATER TUBE...

Page 558: ... tighten the 6 x 12 mm flange bolt 4 Install the under cover seal B extension case grommet and the two dowel pins on the extension case Install the under cover seal B underside the projections of the extension case securely 5 Apply grease to the inner wall of the vertical shaft bushing Install the vertical shaft bushing 26 mm washer and the circlip in the extension case XC XCC XD and XCD types onl...

Page 559: ...se ThreeBond 5222B or equivalent 8 Apply grease to the water tube end Install the extension case on the outboard motor aligning the water tube with the extension case grommet 9 Tighten the eight 10 x 40 mm flange bolts to the specified torque TORQUE 39 N m 4 0 kgf m 29 lbf ft 1 EXTENSION CASE 2 Sealant ThreeBond 5222B application area 3 EXTENSION CASE 2 EXTENSION CASE GROMMET 10 x 40 8 1 WATER TUB...

Page 560: ...UE 83 N m 8 5 kgf m 61 lbf ft NOTICE 12 Connect the ground cable with the 6 x 12 mm flange bolt 13 Install the lower mount housing on the extension case and tighten the three 8 mm washers and the three 8 x 30 mm hex bolts 14 Remove the hoist hooks from the engine hangers and lower the outboard motor to the lowermost position 15 Install the following pars Gear case assembly P 14 5 and 44 L R engine...

Page 561: ...case P 3 2 2 Remove the sixteen 10 x 40 mm flange bolts and remove the oil case from the mount case 6 OIL STRAINER 1 OIL LEVEL PIPE 2 OIL LEVEL GAUGE 6 x 12 4 6 x 10 mm DOWEL PIN 2 9 OIL CASE 10 OIL PAN GASKET 6 x 18 2 10 x 40 16 34 N m 3 5 kgf m 25 lbf ft 7 OIL DRAIN PLUG BOLT 23 N m 2 3 kgf m 17 lbf ft 8 12 mm DRAIN PLUG WASHER Do not reuse 5 20 6 x 2 6 mm O RING Do not reuse 3 11 5 x 3 5 mm O R...

Page 562: ... been left unassembled for 90 minutes remove the old gasket and apply a new gasket again Do not fill in the oil case with the engine oil for 15 minutes after assembly NOTICE 3 Apply engine oil to the circumference of the new 20 6 x 2 6 mm O ring and install it on the oil strainer 4 Install the oil pan gasket on the mount case Install the oil strainer and tighten the two 6 x 18 mm flange bolts 2 OI...

Page 563: ...il level gauge 8 Tighten the 10 x 40 mm flange bolts to the specified torque in the numbered sequence in two or three steps TORQUE 34 N m 3 5 kgf m 25 lbf ft 9 Tighten the 12 mm drain plug washer and the oil drain plug bolt on the oil case Tighten them to the specified torque and add the engine oil TORQUE 23 N m 2 3 kgf m 17 lbf ft 10 Install the following parts Extension case lower rubber mount P...

Page 564: ... POWER TRIM TILT ASSEMBLY 4 POWER TRIM TILT ASSEMBLY 5 AIR BLEEDING 6 BLOW PRESSURE INSPECTION 7 POWER TILT MOTOR ASSEMBLY 15 MOUNTING CASE STERN BRACKET SWIVEL CASE POWER TRIM TILT ASSEMBLY 83 N m 8 5 kgf m 61 lbf ft 34 N m 3 5 kgf m 25 lbf ft 34 N m 3 5 kgf m 25 lbf ft 34 N m 3 5 kgf m 25 lbf ft ...

Page 565: ... Engine cover P 4 2 L R engine under covers P 4 9 Under cover front bracket P 4 20 Water relief tube C P 8 6 Engine assembly P 7 2 Remove the two 12 mm self locking nuts and remove the mounting case assembly 1 12 mm SELF LOCKING NUT 2 2 MOUNTING CASE ASSEMBLY ...

Page 566: ...cut and replace if necessary before removal Remove the 14 x 26 x 8 mm water seal using a commercially available oil seal remover Replace with a new one on assembly 5 Remove the two 12 x 145 mm stud bolts from the upper rubber mount 6 Remove the six 8 x 35 mm flange bolts and remove the upper mount holder upper mount holder gasket and the upper rubber mount Replace the gasket with a new one on asse...

Page 567: ... bearing in the mounting case using the special tools and the hydraulic press as shown TOOLS Driver 07749 0010000 Attachment 28 x 30 mm 07946 1870100 Pilot 20 mm 07746 0040500 e MOUNTING CASE ASSEMBLY 1 Install the upper rubber mount in the mounting case with the UP mark on the upper rubber mount toward up and the white paint mark toward the opposite side from the water seal installation part Note...

Page 568: ...allation direction 3 Tighten the upper rubber mount securely with the six 8 x 35 mm flange bolts 4 Tighten the two 12 x 145 mm stud bolts on the upper rubber mount securely with the longer threads of the stud bolts toward the upper rubber mount side 2 12 x 145 mm STUD BOLT 2 3 12 x 145 mm STUD BOLT 3 UPPER MOUNT HOLDER GASKET 2 CUTOUTS 1 UPPER MOUNT HOLDER 8 x 35 6 4 WATER SEAL INSTALLATION PART 5...

Page 569: ...x 26 x 8 mm water seal 9 Install the water seal with the special tools as shown Note the installation direction 10 After installing the water seal apply 2 4 g 0 07 0 14 oz of grease to the lip and the area around the lip of the water seal Note the installation direction of the water seal TOOLS Driver 07749 0010000 Attachment 24 x 26 mm 07746 0010700 Pilot 12 mm 07746 0040100 2 Apply grease to the ...

Page 570: ...ch mark on the shift shaft B with the punch mark on the shift shaft A as shown 11 Apply grease to the shift shaft A installation part in the mounting case 12 Set the shift shaft A on the mounting case and install the 14 mm washer and the 12 mm E ring on the shift shaft A 2 SHIFT SHAFT WASHER 1 SHIFT SHAFT B 1 SHIFT SHAFT B 3 SHIFT SHAFT A 4 PUNCH MARKS 2 14 mm WASHER 1 SHIFT SHAFT A 3 12 mm E RING...

Page 571: ...ket If it has been left for 90 minutes or longer remove the old gasket and apply a liquid gasket again before installation 17 Install the idle exhaust port gasket on the mounting case and tighten the three 6 x 25 mm flange bolts securely NOTICE 18 Install the mounting case rubber seal on the mounting case with the cut side to your side 19 Install the under cover seal A on the mounting case P 15 3 ...

Page 572: ...cking nut to the specified torque TORQUE 83 N m 8 5 kgf m 61 lbf ft 2 Remove the following parts Engine assembly P 7 6 Water relief tube C P 8 7 Under cover front bracket P 4 31 L R engine under covers P 4 14 Engine cover P 4 2 2 MOUNTING CASE ASSEMBLY 1 12 mm SELF LOCKING NUT 2 83 N m 8 5 kgf m 61 lbf ft ...

Page 573: ... bracket A Disconnect the trim angle sensor 3P connector and the power tilt motor 2P connector 3 Remove the undercase grommet C outside the under cover front bracket Pull off the tube and wires through the hole in the under cover front bracket 4 Hook the hoist hook on each of the three engine hangers Remove the following part Lower rubber mount P 14 89 Check that the outboard motor is not lifted o...

Page 574: ...lowering the outboard motor slowly with the hoist Do not raise the outboard motor stand off the ground while raising the outboard motor with the hoist Remove the stern bracket swivel case assembly with care not to damage the threads of the two 12 x 145 mm stud bolts 7 After removing the stern bracket swivel case assembly lower the outboard motor slowly Store the outboard motor with the extension c...

Page 575: ...e attached to the outboard motor stand slowly toward the outboard motor Insert the 12 x 145 mm stud bolts into the mount frame and tighten the two 12 mm self locking nuts to the specified torque TORQUE 83 N m 8 5 kgf m 61 lbf ft 3 Install the lower rubber mount P 14 93 4 Detach the hoist hooks from the three engine hangers 2 HOIST CHAIN 3 ENGINE HANGER 2 1 ENGINE HANGER B 2 STERN BRACKET SWIVEL CA...

Page 576: ...NNECTOR BRACKET A 2 TRIM ANGLE SENSOR 3P CONNECTOR 1 POWER TILT MOTOR 2P CONNECTOR 5 Pass the tube and wires through the hole in the under cover front bracket Check that the taped ends of the power tilt motor wire and trim angle sensor wire are in alignment with the end of the undercase grommet C Install the undercase grommet C on the under cover front bracket so they engage securely in the groove...

Page 577: ...e uppermost position secure it in the position with the tilt stopper Tighten the manual valve 2 Open the wire harness clip and release the trim angle sensor wire power tilt motor wire and the speed sensor tube A Remove the spiral tube from the trim angle sensor wire power tilt motor wire and the speed sensor tube A 3 Remove the wire band from the undercase grommet C and release the trim angle sens...

Page 578: ...ation and cracks Replace if necessary 3 JOINT A 4 WIRE BAND 2 2 SPEED SENSOR TUBE B 1 SPEED SENSOR TUBE A 5 Remove the motor wire bushing from the L stern bracket 1 L STERN BRACKET 2 MOTOR WIRE BUSHING 6 Remove the two 6 x 25 mm hex bolts and the two 6 mm washers and remove the anode metal Check the anode metal for corrosion If it is corroded excessively replace with a new one 1 ANODE METAL 2 6 mm...

Page 579: ...ube B Check the speed sensor tube B for deterioration and cracks Replace if necessary 2 6 x 8 mm SCREW 2 3 SPEED SENSOR TUBE PLATE 2 1 SPEED SENSOR TUBE B 8 Remove the 10 mm self locking nut and 10 mm washer and remove the 10 x 235 mm hex bolt 3 10 x 235 mm HEX BOLT 2 10 mm WASHER 1 10 mm SELF LOCKING NUT ...

Page 580: ...od of the power trim tilt assembly If it is damaged replace with a new one 10 Remove the upper cylinder bushing Replace with a new one on assembly 3 SWIVEL CASE ASSEMBLY 4 PISTON ROD 2 UPPER CYLINDER PIN 1 15 mm E RING 2 11 Remove the two 6 x 20 mm hex bolts and the two 6 mm washers from the trim angle sensor and remove the trim angle sensor 3 6 mm WASHER 2 2 6 x 20 mm HEX BOLT 2 1 TRIM ANGLE SENS...

Page 581: ...new ones on assembly Do not push in the piston rod after removing the power trim tilt assembly If the piston rod is pushed down extend the piston rod fully and hold it in the position Store the power trim tilt assembly vertically with the upper cylinder pin installation part facing up after removal Never store the power trim tilt assembly by laying it on its side or with the lower cylinder collar ...

Page 582: ...e bushing with a new one on assembly 19 Remove the 15 54 x 2 26 mm O ring from the tilting shaft Replace the O ring with a new one on assembly Remove the wire harness clip from the L stern bracket 9 25 x 2 0 mm SELF LOCKING NUT 10 26 mm WAVE WASHER 2 6 R STERN BRACKET 7 L STERN BRACKET 4 TILTING SHAFT 11 SWIVEL CASE BUSHING 1 SWIVEL CASE ASSEMBLY 3 TILTING BOLT CAP 2 7 8 14 UNF SELF LOCKING NUT b ...

Page 583: ...MOTOR WIRE BUSHING 6 ANODE METAL 8 6 mm WASHER 2 7 6 x 25 mm HEX BOLT 2 15 6 x 8 mm SCREW 2 16 SPEED SENSOR TUBE PLATE 2 14 WIRE HARNESS CLIP 11 JOINT A 12 WIRE BAND 2 2 SPEED SENSOR TUBE B 13 SPEED SENSOR TUBE A 10 SPEED SENSOR TUBE B 4 10 mm SELF LOCKING NUT 34 N m 3 5 kgf m 25 lbf ft ...

Page 584: ...ER CYLINDER COLLAR 18 6 mm WASHER 2 19 6 x 20 mm HEX NUT 2 17 TRIM ANGLE SENSOR 2 SWIVEL CASE ASSEMBLY 1 UPPER CYLINDER PIN 3 15 mm E RING 2 15 L STERN BRACKET 8 26 mm WAVE WASHER 2 10 UPPER CYLINDER BUSHING 2 7 15 54 x 2 26 mm O RING 6 7 8 14 UNF SELF LOCKING NUT 34 N m 3 5 kgf m 25 lbf ft 16 25 x 2 5 mm SELF LOCKING NUT 34 N m 3 5 kgf m 25 lbf ft ...

Page 585: ...39 mm EXTERNAL CIRCLIP 2 GROUND CABLE 1 6 x 8 mm SCREW 3 Remove the lower mount center housing using a hydraulic press and the special tools as shown TOOLS Driver 07749 0010000 Attachment 32 x 35 mm 07746 0010100 Pilot 30 mm 07746 0040700 4 LOWER MOUNT CENTER HOUSING 2 PRESS 4 LOWER MOUNT CENTER HOUSING 1 MARK 3 MARK 2 MOUNT FRAME 1 DRIVER 07749 0010000 5 ATTACHMENT 32 x 35 mm 07746 0010100 3 PILO...

Page 586: ... 5 Check the 39 5 x 52 x 6 mm oil seal lip for cut and replace if necessary before removing the oil seal Remove the 39 5 x 52 x 6 mm oil seal from the swivel case using a commercially available oil seal remover Replace the oil seal with a new one on assembly 6 Remove the two swivel case liners from the swivel case 1 SWIVEL CASE LINER 2 3 39 5 x 52 x 6 mm OIL SEAL 2 SWIVEL CASE ...

Page 587: ...not interfere with the swivel case as shown Remove the driven out 2 5 x 20 mm spring pin using the cutting pliers or equivalent tool Remove the spring pin on the other side in the same manner 11 Remove the two tilt stoppers and the tilting bracket Check the tilt arm bushings mounted on the swivel case Replace them with the new ones if they are damaged 12 Remove the tilt arm bushings Replace the ti...

Page 588: ...TILT STOPPER 2 5 2 5 x 20 mm SPRING PIN 2 1 DETENT SPRING 3 DETENT ASSISTED SPRING 2 6 x 14 mm HEX BOLT 16 40 mm WAVE WASHER 19 34 mm THRUST WASHER 4 SWIVEL CASE LINER 2 17 39 5 x 52 x 6 mm OIL SEAL 15 39 mm EXTERNAL CIRCLIP 14 GROUND CABLE 13 6 x 8 mm SCREW 12 LOWER MOUNT CENTER HOUSING 20 MOUNT FRAME 21 GREASE FITTING 3 3 N m 0 3 kgf m 2 2 lbf ft ...

Page 589: ...0 04 0 08 in 4 Apply grease to the cam of the tilting bracket 5 Apply grease to the detent spring roller Secure the detent spring and the detent assisted spring with the 6 x 14 mm hex bolt 2 PROJECTION 1 2 mm 0 04 0 08 in 3 DRIVE IN DIRECTION 4 2 5 x 20 mm SPRING PIN 2 1 2 5 mm PIN DRIVER Commercially available 6 Install the two thrust receivers on the swivel case then install the two 10 mm washer...

Page 590: ...IVEL CASE LINER 4 SWIVEL CASE LINER 5 39 5 x 52 x 6 mm OIL SEAL 3 PROJECTION 1 CONCAVE 3 PROJECTION 1 CONCAVE 2 SWIVEL CASE 2 SWIVEL CASE 10 Apply grease to the surface of the 34 mm thrust washer and install it on the mount frame Apply grease to the entire surface of the mount frame shaft and install the mount frame on the swivel case Install the mount frame with care not to push the swivel case l...

Page 591: ...embly 13 Position the swivel case mount frame on the hydraulic press as shown 14 Position the special tool on the lower mount center housing as shown Press fit the lower mount center housing until it contacts the swivel case i e hydraulic pressure of the hydraulic press rises slightly TOOL Driver 40 mm I D 07746 0030100 2 LOWER MOUNT CENTER HOUSING 4 LOWER MOUNT CENTER HOUSING 1 MARK 3 MARK 2 MOUN...

Page 592: ...ller bolt and align the surface of the lower mount center housing with the circlip installation groove in the mount frame Remove the puller and the special tool 3 Install the 39 mm external circlip and apply grease to the part A shown in the drawing 2 PART A 8 CIRCLIP INSTALLATION GROOVE 9 ENLARGED VIEW OF MOUNT FRAME 1 39 mm EXTERNAL CIRCLIP 6 LOWER MOUNT CENTER HOUSING 17 Tighten the 6 x 8 mm sc...

Page 593: ...6 mm wave washer and the stern bracket 6 Loosely tighten the new 25 x 2 0 mm self locking nut or the 7 8 24 UNF self locking nut on the tilting shaft Move the L R stern brackets to the self locking nut side Raise the swivel case assembly to the uppermost position and hold it in the position with the tilt stopper Install the wire harness clip on the L stern bracket 7 Apply grease to the inner wall ...

Page 594: ...the trim angle sensor wire power tilt motor wire and the speed sensor tube B through the motor wire bushing Install the motor wire bushing in the L stern bracket aligning the projection on the motor wire bushing with the concave in the L stern bracket Check that the speed sensor tube B is at the rear side in the motor wire bushing compared with the position of the trim angle sensor wire and the po...

Page 595: ...e A to the joint A and fasten the new wire band on the speed sensor tube A Connect the speed sensor tube B to the joint A and fasten the new wire band on the speed sensor tube B 17 Adjust the distance from the end of the motor wire bushing to the end of the speed sensor tube B so that it is 10 15 mm 0 4 0 6 in as shown 10 15 mm 0 4 0 6 in 2 WIRE BANDS 1 MOTOR WIRE BUSHING 5 SPEED SENSOR TUBE B 3 S...

Page 596: ...NGLE SENSOR WIRE 4 L STERN BRACKET 8 WIRE HARNESS CLIP 7 SPEED SENSOR TUBE A 3 MOTOR WIRE BUSHING 20 Pass the trim angle sensor wire power tilt motor wire and the speed sensor tube A through the undercase grommet C 21 Align the taped ends of the trim angle sensor wire and the power tilt motor wire with the end of the undercase grommet C and fasten the new wire band as shown After fastening the wir...

Page 597: ... ROD 2 UPPER CYLINDER PIN 1 15 mm E RING 2 5 UPPER CYLINDER BUSHING 2 22 Apply grease to the inner wall and circumference of the new upper cylinder bushings and install them on the piston rod of the power trim tilt assembly 23 Apply grease to the circumference of the upper cylinder pin 24 Align the hole in the piston rod with the hole in the swivel case assembly and insert the upper cylinder pin i...

Page 598: ...m WASHER 2 3 6 x 25 mm HEX BOLT 2 27 If the manual valve is tightened loosen it fully Raise the swivel case assembly a little unlock the tilt stopper and lower the swivel case assembly to the lowermost position 28 Remove the following parts Stern bracket swivel case P 15 12 Gear case assembly P 14 5 and 44 L R engine under covers P 4 14 Engine cover P 4 2 1 MANUAL VALVE ...

Page 599: ... Store the parts neatly keeping them off dust dirt oil grease etc Remove the piston rod comp and the piston rod B with care not to damage the sliding surface of the parts With the power trim tilt assembly removed from the outboard motor connect the power tilt motor 2P connector and operate the power tilt motor until the piston rod comp and the piston rod B reach the fully extended position 1 Remov...

Page 600: ...embly Check the mesh of the filter B for blockage and tear If it is torn replace the filter B with a new one If it is clogged with dust and dirt blow the mesh with air to remove the blockage Take care not to damage the mesh Drain the residual Automatic Transmission Fluid ATF from the pump assembly 3 PUMP ASSEMBLY 2 FILTER B 1 DRIVE JOINT 7 Remove the socket bolt A and Bs and remove the pump assemb...

Page 601: ...the trim cylinders Remove the rod guide comps from the piston rod B 8 Remove the internal circlip and remove the manual valve from the pump assembly Check the manual valve and the O ring for deterioration wear and damage Replace them if necessary Replace the manual valve with a new one on assembly 3 PUMP ASSEMBLY 2 MANUAL VALVE 1 INTERNAL CIRCLIP 9 Set the cylinder comp in a vice as shown Do not t...

Page 602: ...w one 3 O RING 2 BACKUP RING 1 PISTON ROD B 14 Remove the O ring from the rod guide comp Replace the O ring with a new one on assembly 15 Insert a sharp end screwdriver into the gap between the dust seal and the rod guide comp Raise the dust seal and remove it from the rod guide comp Remove the oil seal in the rod guide comp in the same manner Replace the dust seal and the oil seal with the new on...

Page 603: ... cylinder comp Check the sliding surface of the free piston for wear and damage Replace the free piston if necessary 24 Remove the backup ring and the O ring from the free piston Replace the backup ring and the O ring as a set on assembly Drain the residual Automatic Transmission Fluid ATF from the cylinder comp 1 FREE PISTON 4 O RING 2 BACKUP RING 3 CYLINDER COMP c INSPECTION POWER TILT MOTOR Che...

Page 604: ...ER TILT MOTOR ASSEMBLY 27 FILTER B 26 DRIVE JOINT 20 ORIFICE COLLAR 19 O RING 5 9 OIL TANK 24 MANUAL VALVE 3 5 N m 0 35 kgf m 2 5 lbf ft 1 HEX BOLT 4 5 N m 0 5 kgf m 3 6 lbf ft 10 HEX BOLT 3 5 N m 0 5 kgf m 3 6 lbf ft 5 CYLINDER CAP 162 N m 16 5kgf m 119 lbf ft 11 OIL TANK CAP 2 5 N m 0 25 kgf m 1 8 lbf ft 14 ROD GUIDE COMP 2 78 N m 8 0 kgf m 58 lbf ft 22 SOCKET BOLT A 8 5 N m 0 85 kgf m 6 1 lbf f...

Page 605: ...matic Transmission Fluid ATF When the operation is made by holding the cylinder comp in a vice do not tighten the vice excessively It can damage the cylinder comp Add the Automatic Transmission Fluid ATF slowly Assemble the power trim tilt assembly with the piston rod comp and the piston rod B fully extended Do not push in the piston rod comp and the piston rod B Do not allow the dust dirt and oth...

Page 606: ...stall the piston rod comp slowly in the piston rod chamber of the cylinder comp Loosely tighten the cylinder cap Do not install the piston rod comp by pushing it in the piston rod chamber 9 Tighten the cylinder cap to the specified torque using the special tool as shown TOOL Pin wrench 6 mm 07SPA ZW10100 TORQUE 162 N m 16 5 kgf m 119 lbf ft 10 Pour the fresh Automatic Transmission Fluid ATF in the...

Page 607: ...tall it in the upper groove in the rod guide comp 14 Apply Automatic Transmission Fluid ATF to the new O ring and install it on the rod guide comp 15 Install the rod guide comp on the piston rod B Extend the piston rod fully and hold it in the position 16 Holding the piston rod Bs aslant a little set each of piston rod Bs in the left and right trim cylinder chambers Do not install the piston rod B...

Page 608: ... N m 0 35 kgf m 2 5 lbf ft 22 Install the internal circlip securely in the groove in the pump assembly 23 Apply Automatic Transmission Fluid ATF to the five new O rings and the orifice collar Set the five O rings and the orifice collar in the indicated position of the cylinder comp 24 Install the pump assembly on the cylinder comp with the socket bolt A and B Tighten the socket bolt A and B to the...

Page 609: ...e air in the system 28 After removing the air bubbles fill the pump assembly fully with the Automatic Transmission Fluid ATF again 1 OIL BOTTLE 30 Install the power tilt motor assembly on the pump assembly aligning the projection on the power tilt motor assembly with the recess in the drive joint and with the motor wire of the power tilt motor assembly at the manual valve side 29 Apply Automatic T...

Page 610: ...t of the filler port will overfill the tank and that will damage the oil seal of the motor when each rod is compressed 35 After filling the oil tank with Automatic Transmission Fluid ATF bleed air from the power trim tilt assembly without mounting on the outboard motor P 15 48 36 Tighten the oil tank cap to the specified torque TORQUE 2 5 N m 0 25 kgf m 1 8 lbf ft NOTICE 31 Set the four hex bolts ...

Page 611: ...d extended fully Check whether the Automatic Transmission Fluid ATF is at the upper limit of the oil tank filler port If Automatic Transmission Fluid ATF does not flow out of the filler port add Automatic Transmission Fluid ATF up to the upper limit of the filler port using a syringe or equivalent tool Check the fluid level with the rods fully extended Note that Automatic Transmission Fluid ATF wi...

Page 612: ...tion P 15 50 4 If the rods do not compress fully after the above operation disassemble P 15 36 and reassemble P 15 42 the power trim tilt assembly and bleed air with the power trim tilt assembly not mounted on the outboard motor P 15 48 Air bleeding with power trim tilt assembly mounted on the outboard motor Perform the following procedure after bleeding air without mounting the power trim tilt as...

Page 613: ... pressure at the upper and lower chambers of the cylinder a LOWER CHAMBER BLOW PRESSURE 1 Remove the internal circlip and manual valve from the power trim tilt assembly Note that Automatic Transmission Fluid ATF will spurt out when the manual valve is removed without the rods fully extended Move each rod to the fully extended position before removing the manual valve A small amount of the Automati...

Page 614: ...sure gauge joint A quickly 2 Attach the special tool oil pressure gauge joint A for measurement of upper chamber blow pressure to the manual valve installation section as shown Tighten the special tool to the specified torque TOOL Oil pressure gauge joint A 07SPJ ZW10100 TORQUE 9 N m 0 9 kgf m 6 5 lbf ft 3 Attach a commercially available pressure gauge P T 1 4 which measures 14 710 kPa 150 kgf cm2...

Page 615: ...ing a syringe or equivalent tool P 15 47 4 Remove the oil tank cap Check that Automatic Transmission Fluid ATF is at the upper limit of the filler port P 15 47 5 Push the DN side of the power tilt switch to compress each rod fully Read the pressure gauge to measure the upper chamber blow pressure 6 If the blow pressure is lower than the specified pressure check each part of the power trim tilt ass...

Page 616: ...isconnect the motor wire blue wire terminal from the breaker assembly while holding the breaker assembly with a screwdriver Do not disconnect the blue wire terminal without holding the breaker assembly or it can cause damage to the brush holder B Be sure to disconnect the terminal while holding the breaker assembly 8 Remove the 4 x 10 mm screw from the brush holder A and remove the brush assembly ...

Page 617: ...SH SPRING 2 11 FRONT BRACKET 10 FRONT BRACKET ASSEMBLY 9 OIL SEAL 7 O RING 14 MOTOR WIRE Green wire 15 MOTOR WIRE Blue wire 4 YOKE ASSEMBLY 1 ARMATURE 8 4 x 16 mm SCREW 2 5 4 x 10 mm SCREW 2 2 CORRUGATED TUBE 3 4 x 16 mm SCREW Stainless steel 1 4 N m 0 14 kgf m 1 0 lbf ft ...

Page 618: ... the front bracket assembly if there is no operation sound from the breaker assembly 2 ARMATURE 3 BREAKER ASSEMBLY 1 BRACKET HOLDER MICA DEPTH If the grooves are clogged or mica depth is less than the service limit recut the groove using a hacksaw blade or a small file If the mica depth is still less than the service limit replace the armature ARMATURE Use the armature tester if it is available CO...

Page 619: ... TEST SHAFT TO COMMUTATOR Check for continuity between the commutator and armature shaft If there is continuity replace the armature SHORT CIRCUIT TEST ARMATURE Place the armature on an armature tester Hold a hacksaw blade close to the armature core If the blade is attracted to the core or vibrates when the core is turned the armature is shorted Replace the armature ...

Page 620: ...rminal contact the respective projections on the brush holder A then tighten the 4 x 10 mm screw securely 4 Check that the commutator surface is not contaminated with oil and grease Set the two brush springs on the front bracket assembly and install the armature on the front bracket with the brush terminal pushed in the holder 5 Wrap the armature shaft with a shop towel or equivalent material and ...

Page 621: ...ot to overtighten it TORQUE 1 4 N m 0 14 kgf m 1 0 lbf ft 9 Tape the corrugated tube with the heat resisting tape so that the distance from the wire holder end to the corrugated tube end is 30 mm 1 2 in or less as shown 10 Install the power tilt motor assembly on the power trim tilt assembly P 15 46 Coat the joints or mating sections of the parts and the sections where the paint came off with rust...

Page 622: ...NSPECTION 1 STEERING ROD a REMOVAL INSTALLATION 2 TILTING BOLT CAP 1 STEERING CABLE 4 MOUNT FRAME 8 STEERING ROD COLLAR 6 STEERING ROD 7 10 mm WASHER 4 3 3 8 24 UNF BOLT 5 3 8 24 UNF SELF LOCKING NUT 2 22 N m 2 2 kgf m 16 lbf ft 16 STEERING ROD REMOTE CONTROL BOX 22 N m 2 2 kgf m 16 lbf ft ...

Page 623: ...EMOTE CONTOL CABLE Throttle side 5 CABLE CLAMP SPACER 10 REMOTE CONTROL BOX COVER C 7 REMOTE CONTOL BOX COVER B 8 FAST IDLE LEVER 9 5 x 12 mm OVAL SCREW 2 6 REMOTE CONTROL CABLE Shift side ADJUSTMENT P 3 24 1 SHIFT PIVOT 2 INSTALLATION Screw in the shift pivot 8 mm or more onto the threaded end of the cable 1 1 8 mm or more ADJUSTMENT P 3 26 ...

Page 624: ...ON P 16 9 4 16 mm HEX NUT 1 5 N m 0 15 kgf m 1 1 lbf ft 8 22 mm NUT 7 INDICATOR LIGHT OIL PRESSURE LIGHT OVERHEAT LIGHT INSPECTION P 16 9 11 5 x 8 mm SELF TAPPING SCREW 2 10 POWER TILT CORD CLAMP 9 SPARE EMERGENCY STOP SWITCH CLIP 4 8 N m 0 49 kgf m 3 5 lbf ft 6 20 mm HEX NUT 1 WARNING BUZZER INSPECTION P 16 10 ...

Page 625: ...SELF TAPPING SCREW 22 4 x 10 mm SELF TAPPING SCREW 20 SWITCH START CAM 23 SPRING SETTING PLATE 3 5 mm WASHER 21 4 mm WASHER 2 FAST IDLE WHEEL 3 5 mm WASHER 4 5 x 10 mm SCREW 5 4 mm E CLIP 7 7 mm E CLIP 6 6 mm WASHER 2 8 8 mm WASHER 9 5 mm HEX NUT 10 5 x 16 mm HEX BOLT 11 6 x 10 mm SCREW 17 12 7 x 23 9 mm FAST IDLE DETENT SPRING 18 CONTROL WHEEL 12 LINK JOINT BRACKET 13 LINK JOINT ARM 14 LINK JOINT...

Page 626: ...m HEX BOLT 1 8 mm WASHER 21 CONTROL WHEEL 20 28 mm WASHER 19 SHIFT LINK ARM 18 9 8 x 27 1 mm SHIFT DETENT SPRING 17 9 x 10 mm SHIFT DETENT ROLLER 16 REMOTE CONTROL BOX HOUSING A 15 NEUTRAL LOCK BLOCK 14 REMOTE CONTROL LEVER ASSEMBLY 5 5 x 10 mm SELF TAPPING SCREW 5 5 x 10 mm SELF TAPPING SCREW 13 6 x 16 mm SELF TAPPING SCREW 2 11 SPRING SETTING PLATE 4 6 mm HEX NUT 10 3 mm E RING ...

Page 627: ...5 LEVER SETTING PLATE 9 REMOTE CONTROL LEVER 8 WIRE HARNESS CLIP 7 5 x 12 mm OVAL SCREW 6 LEVER CAP 4 5 x 10 mm SCREW 10 5 x 12 mm SELF TAPPING SCREW 2 REMOTE CONTROL LEVER SPRING 1 REMOTE CONTROL LEVER GRIP 11 POWER TRIM TILT SWITCH INSPECTION P 16 10 ...

Page 628: ... 2 BUZZER BRACKET 6 SWITCH PANEL CABLE 4 WIRE HARNESS BAND 10 5 mm FLANGE NUT 4 9 EMERGENCY STOP SWITCH INSPECTION P 16 9 8 WARNING BUZZER INSPECTION P 16 10 7 TIE CABLE 2 Do not reuse 5 SWITCH PANEL HARNESS CONNECTION P 16 8 3 IGNITION SWITCH INSPECTION P 16 9 1 INDICATOR LIGHT MIL ALTERNATOR INDICATOR LIGHT INSPECTION P 16 9 16 16 mm HEX NUT 1 5 N m 0 15 kgf m 1 1 lbf ft 4 9 N m 0 49 kgf m 3 5 l...

Page 629: ...es to the respective switches as shown 16 8 9 IGNITION SWITCH 10 INDICATOR LIGHT 8 EMERGENCY STOP SWITCH 3 To EMERGENCY STOP SWITCH 4 To METER HARNESS 1 To SWITCH PANEL CABLE 2 To POWER TRIM TILT SWITCH 5 SWITCH PANEL HARNESS SIDE 6 CONTROL PANEL SIDE 7 WARNING BUZZER ...

Page 630: ...o the switch 1 2 and 3 respectively and apply 12V battery voltage to the black yellow gray terminal When the switch 1 is ON Green light is ON When the switch 2 and 3 are ON Green light is ON When the switch 2 is ON Red light is ON Color in the brackets is for the side mount remote control type only NOTICE INDICTOR LIGHT MIL ALTERNATOR INDICATOR LIGHT Use a known good battery Connect the white blue...

Page 631: ...positive terminal and the yellow green terminal to the battery negative terminal as shown Check that the buzzer sounds this time NOTICE POWER TRIM TILT SWITCH Side mount remote control type only Check for continuity between the terminals with the switch in each position Continuity Lb Light blue W White Bl Black Lg Light green Lb W Bl Lg UP DN DOWN ...

Page 632: ...17 1 1 REMOTE CONTROL CABLE GROMMET 2 SHIFT LINK BRACKET NEUTRAL SWITCH 3 SEAL HOLDER 17 CABLES SHIFT LINK BRACKET SHIFT ARM NEUTRAL SWITCH 2 5 N m 0 25 kgf m 1 8 lbf ft ...

Page 633: ...IFT PIVOT 2 3 REMOTE CONTROL CABLE Shift side 2 REMOTE CONTROL CABLE 14P CONNECTOR 1 INDICATOR LIGHT 6P CONNECTOR 3 NEUTRAL SWITCH BRACKET 1 REMOTE CONTROL CABLE GROMMET a REMOVAL Remove the following parts Engine cover P 4 2 Front separate cover P 4 7 1 Remove the remote control cable shift side shift pivot from the shift arm shift link pin 2 Remove the remote control cable throttle side shift pi...

Page 634: ...REMOTE CONTROL CABLE GROMMET 4 UNDER COVER FRONT BRACKET 7 6 mm WASHER 1 6 x 16 mm HEX BOLT 2 REMOTE CONTROL CABLE PLATE 4 FUEL TUBE A 5 STARTER CABLE 6 STARTER CABLE 5 CABLE BRACKET A 1 INDICATOR LIGHT WIRE 2 REMOTE CONTROL CABLE 3 SPEED SENSOR TUBE A 6 REMOTE CONTROL CABLE GROMMET 6 Remove the speed sensor tube A remote control cable indicator light wire starter cable and the fuel tube A from th...

Page 635: ... SENSOR TUBE A 14 REMOTE CONTROL CABLE GROMMET 16 6 mm WASHER 17 6 x 16 mm HEX BOLT 15 REMOTE CONTROL CABLE PLATE 3 REMOTE CONTROL CABLE Throttle side 1 SHIFT PIVOT 2 2 LOCK NUT 2 4 REMOTE CONTROL CABLE Shift side 13 FRONT SEPARATE COVER 12 6 x 25 mm SCREW 3 10 6 x 17 mm SPECIAL BOLT 11 UNDERCASE GROMMET BAND ...

Page 636: ...d of the white tape on the starter cable with the end of the under cover front bracket as shown 3 Set the fuel tube A and the speed sensor tube A in the specified positions of the remote control cable grommet 3 STARTER CABLE 6 INDICATOR LIGHT WIRE 5 REMOTE CONTROL CABLE 7 REMOTE CONTROL CABLE GROMMET 4 TIE WIRES 2 WHITE TAPE 1 UNDER COVER FRONT BRACKET 4 FUEL TUBE A 1 INDICATOR LIGHT WIRE 2 REMOTE...

Page 637: ...the starter cable with the cable bracket A 5 Connect the indicator light 6P connector and the remote control cable 14P connector Install the indicator light 6P connector and the remote control cable 14P connector on the neutral switch bracket 2 REMOTE CONTROL CABLE 14P CONNECTOR 1 INDICATOR LIGHT 6P CONNECTOR 3 NEUTRAL SWITCH BRACKET 4 REMOTE CONTROL CABLE GROMMET 6 UNDER COVER FRONT BRACKET 10 6 ...

Page 638: ...he center of the neutral switch end is not in line with the center of the flat part of the detent arm check the detent arm Replace the detent arm with a new one if it is deformed or damaged 1 Install the shift pivot on the remove control cable shift side Apply marine grease to the mounting part of the shift link pin on the shift pivot and to the shift link pin 2 Check that the remote control cable...

Page 639: ...of the cable outer seal of the inner cable 6 Mark C at the midpoint between the mark A and the mark B 7 Align the mark C marked in step 6 with the end of the cable outer seal 8 Move the shift link pin end lightly right and left If the shift link pin has a free play set the shift link pin at the center of the free play 2 N NEUTRAL 1 R REVERSE 3 MARK B 2 MARK A 1 MARK B 3 MARK C 1 MARK C 1 SHIFT LIN...

Page 640: ... the gear is not in neutral by moving the remote control lever from the F Forward to the N Neutral position remove the shift side remote control cable from the shift link pin and move the inner cable toward the mark A Repeat the procedure from the step 8 P 17 8 12 If the gear is not in neutral by moving the remote control lever from the R Reverse to the N Neutral position remove the shift side rem...

Page 641: ... pivot 2 Set the remote control cable throttle side shift pivot on the throttle arm link pin 3 Adjust the throttle control cable throttle link P 3 26 Tighten the shift pivot lock nut securely 4 Install the following parts Front separate cover P 4 7 Engine cover P 4 2 4 SHIFT PIVOT 1 LINK PIN 3 REMOTE CONTROL CABLE Throttle side 2 MARINE GREASE ...

Page 642: ...SNAP RING 2 THROTTLE ROD 2 SHIFT LINK BRACKET NEUTRAL SWITCH a REMOVAL Remove the following parts Engine cover P 4 2 Front separate cover P 4 7 L R engine under cover P 4 9 Remote control cable grommet P 17 2 1 Remove the throttle rod linkage pivot from the throttle plate 2 Remove the two 6 x 18 mm flange bolts from the shift link bracket assembly Remove the link pin of the shift link bracket asse...

Page 643: ...acket 8 Remove the neutral switch 2P connector from the connector bracket A then disconnect the connector 9 Remove the harness band clip that secures the alternator fuse cable from the neutral switch bracket 10 Remove the clip A from the neutral switch wire 3 SHIFT SHAFT B 2 SHIFT ARM 3 DETENT ARM 1 Pull in the direction of the arrow 1 DETENT ARM 6 x 14 2 NEUTRAL SWITCH BRACKET 1 FUEL TUBE HOLDER ...

Page 644: ...necessary 13 Remove the detent arm bushing from the detent arm Replace the bushing with a new one on assembly Check the detent arm for deformation or damage and replace if necessary b INSPECTION NEUTRAL SWITCH Connect the tester between the terminals and push the switch knob There must be continuity when the switch knob is pushed and no continuity when the knob is released 2 NEUTRAL SWITCH BRACKET...

Page 645: ...mm SNAP RING 16 SHIFT ARM 10 NEUTRAL SWITCH BRACKET 5 FUEL TUBE HOLDER 4 FUEL TUBE A 6 CLIP A 8 HARNESS BAND CLIP 9 ALTERNATOR FUSE CABLE 3 CONNECTOR BRACKET A 7 NEUTRAL SWITCH 12 DETENT ARM BUSHING 13 DETENT SPRING 14 DETENT ARM 15 6 mm WASHER 6 x 12 11 20 mm HEX NUT 2 5 N m 0 25 kgf m 1 8 lbf ft 6 x 14 ...

Page 646: ...ot plate 4 Remove the throttle plate 5 Check the two bushing As from the shift link bracket If they are damaged remove them and replace with the new ones 1 THROTTLE LINK 13 LINK PIN 11 SHIFT LINK PIN 9 SHIFT SLIDE PIVOT 8 SHIFT PIVOT PLATE 15 6 mm WASHER 6 8 mm WASHER 14 4 mm E RING 3 7 6 mm E RING 6 x 12 12 PIVOT WASHER 3 THROTTLE PLATE 5 SHIFT LINK BRACKET 4 BUSHING A 2 10 LINK PIN 2 THROTTLE AR...

Page 647: ...e 6 mm washer on the throttle arm and tighten the 6 x 12 mm flange bolt securely 6 Apply marine grease to the mounting part of the throttle arm and the mounting part of the throttle plate in the throttle link then install the throttle link 7 Apply marine grease to the shift slide pivot and the outer surface of the shift link pin Apply marine grease to the entire surface of the link pin Apply marin...

Page 648: ...s shown Align the other hook B with the seal holder hole and install the detent spring 4 Set the 6 mm washer on the detent arm and tighten the 6 x 12 mm flange bolt securely 5 Set the neutral switch on the neutral switch bracket and tighten the 20 mm hex nut to the specified torque TORQUE 2 5 N m 0 25 kgf m 1 8 lbf ft 8 DETENT ARM BUSHING 4 DETENT SPRING 1 6 mm WASHER 6 x 12 9 DETENT ARM 7 HOOK A ...

Page 649: ...by aligning a small hole in the neutral switch bracket with the boss on the seal holder while pulling the detent arm to your side Tighten the 6 x 14 mm flange bolt securely 12 Apply marine grease to the concave in the shift arm and to the shift shaft B Pulling the detent arm to your side install the shift arm on the shift shaft B 1 FUEL TUBE HOLDER 4 CLIP A 7 NEUTRAL SWITCH BRACKET 5 HARNESS BAND ...

Page 650: ...linkage pivot Install the linkage pivot on the throttle plate 17 Apply marine grease to the outer surface of the shift link pin and install the remote control cable shift side P 17 7 18 Apply marine grease to the outer surface of the link pin and install the remote control cable throttle side P 17 10 19 Remove the following parts Remote control cable grommet P 17 5 L R engine under covers P 4 14 F...

Page 651: ...the shift shaft B if it is raised or if it is disengaged from the shift shaft A in the mounting case P 17 21 Note that assembly with the shift shaft A and B out of alignment will prevent proper shifting NOTICE b DISASSEMBLY 1 Before removing the 12 x 26 x 7 mm oil seal check the oil seal lip for cut or other damage Replace if necessary 2 Remove the 12 x 26 x 7 mm oil seal from the seal holder usin...

Page 652: ...17 21 c COMPONENTS DRAWING 6 x 20 2 7 SEAL HOLDER 6 x 14 3 ALTERNATOR FUSE CABLE 4 STARTER CABLE 5 CABLE BRACKET A 6 25 x 2 4 mm O RING 1 12 x 26 x 7 mm OIL SEAL 2 SHIFT SHAFT B ...

Page 653: ...pper NOTICE 2 Raise the shift shaft B slowly while holding the shift shaft A in contact with the stopper in the mounting case 3 With the raised shift shaft B pushed against the stopper in the mounting case lower the shift shaft B slowly and engage it with the shift shaft A Hold the shift shaft A not to move when engaging it with the shift shaft B 4 After correction check for proper shifting of the...

Page 654: ...shift shaft B Correct the shift shaft B if it is raised or if it is disengaged from the shift shaft A in the mounting case P 17 22 Note that assembly with the shift shaft A and B out of alignment will prevent proper shifting 5 Remove the tape from the shift shaft B Check that the oil seal lip is not turned up during removal of the tape 6 Set the starter cable and the alternator fuse cable in the c...

Page 655: ... switch 4 Loosen the 10 x 90 mm flange bolt fully 5 Remove the starter motor together with the 10 x 90 mm flange bolt 6 Remove the O ring from the starter motor Replace the O ring 1 STARTER MOTOR 2 STARTER CABLE 3 ECM PGM FI MAIN RELAY FUSE BOX 4 POWER TILT RELAY CONNECTOR BRACKET A 18 ELECTRICAL EQUIPMENT 8 STARTER MOTOR 3 STARTER CABLE 4 MAIN RELAY TERMINAL W 6 STARTER MAGNETIC SWITCH 5 10 x 90 ...

Page 656: ...CKET ASSEMBLY 4 FRONT BRACKET ASSEMBLY 4 O RING 2 Do not reuse b DISASSEMBLY 1 Move the terminal cover aside Remove the 8 mm washer nut and disconnect the motor wire from the S terminal 2 Remove the 6 x 22 mm washer screws and the O rings Remove the magnetic switch spring and the plunger 3 Remove the two through bolts and remove the yoke rear bracket assembly 4 Remove the gasket and plate ...

Page 657: ...TURE REAR BRACKET ASSEMBLY 1 BRUSH HOLDER 2 REAR BRACKET 2 STEEL BALL 5 Remove the yoke from the armature rear bracket assembly 6 Remove the two 5 x 8 mm screws and remove the rear bracket 7 Remove the brush holder 8 Remove the steel ball and planetary gear ...

Page 658: ... OVERRUNNING CLUTCH DISASSEMBLY 1 Secure the gear shaft by placing a wood block under the gear shaft assembly Secure the gear shaft assembly with care not to contact the internal gear 2 Prepare a pipe of the following dimensions I D approx 11 mm 0 4 in O D approx 15 mm 0 6 in LENGTH approx 20 mm 0 8 in 3 Set the pipe on the gear shaft stopper and drop the gear shaft stopper by tapping on the pipe ...

Page 659: ...he plate 2 Remove the brush sets and the brush springs c INSPECTION BRUSH LENGTH Measure the brush length Replace the brushes as a set if the measurement is less than the service limit 2 BRUSH SET 1 GEAR SHAFT STOPPER 2 ONE WAY CLUTCH 3 GEAR SHAFT 1 PLATE 4 INTERNAL GEAR 4 BRUSH SPRING 4 3 BRUSH HOLDER STANDARD SERVICE LIMIT 12 3 mm 0 48 in 7 0 mm 0 28 in ...

Page 660: ...rmature with a new one 2 Measure the commutator runout using a dial gauge If the measurement is more than the service limit replace the armature with a new one 3 Check the commutator insulaor for damage dust dirt and metal particles If there is stain irregularity and or evidence of burning clean with an emery paper 500 or 600 STANDARD SERVICE LIMIT 0 4 0 5 mm 0 2 mm 0 016 0 020 in 0 008 in STANDAR...

Page 661: ...re If the blade is attracted to the core or vibrates when the core is turned the armature is shorted Replace the armature CONTINUITY CHECK SEGMENTS Check for continuity between each segment If an open circuit exists between any two segments replace the armature SHORT CIRCUIT TEST SHAFT TO COMMUTATOR Check for continuity between the commutator and armature shaft If there is continuity replace the a...

Page 662: ...utch does not move smoothly clean the spline and coat it with grease before recheck If the overrunning clutch does not move smoothly after cleaning or coated with grease replace the overrunning clutch assembly 2 Turn the gear shaft assembly by holding the overrunning clutch The gear shaft assembly should turn only clockwise If the clutch turns freely in both directions or if it does not turn at al...

Page 663: ...18 SPRING 16 GASKET 15 8 mm WASHER NUT 5 PLATE 25 SNAP RING 24 GEAR SHAFT STOPPER 8 ARMATURE 6 REAR BRACKET 14 PLANETARY GEAR 3 17 STARTER MAGNETIC SWITCH 10 OVERRUNNING CLUTCH 11 INTERNAL GEAR 12 GEAR SHAFT 13 STEEL BALL 1 S TERMINAL 2 M TERMINAL 1 BRUSH HOLDER 2 BRUSH SPRING 4 22 FRONT BRACKET 4 BRUSH SET Replace as a set 7 5 x 8 mm SCREW 2 26 6 x 22 mm SCREW 2 23 O RING 2 Do not reuse 9 THROUGH...

Page 664: ... Holding the overrunning clutch push the gear shaft into the overrunning clutch Push the gear shaft stopper up to set the snap ring in the groove of the gear shaft stopper securely 18 10 BRUSH HOLDER ASSEMBLY 1 Install the brush springs and brushes on the brush holder Install the plate on the brush holder 2 Secure the plate with the clip 4 BRUSH SPRING 1 PLATE 3 BRUSH HOLDER 5 CLIP 2 BRUSH SET 2 O...

Page 665: ...f the ring gear with the groove in the front bracket 4 Install the gasket Install by aligning the projections on the gasket with the grooves in the front bracket 5 Apply grease to the planetary gears steel ball and the internal gear 6 Install the planetary gears steel ball and the internal gear 4 CLUTCH FORK 5 FRONT BRACKET 2 OVERRUNNING CLUTCH 3 OVERRUNNING CLUTCH 1 CLUTCH FORK 2 FRONT BRACKET 1 ...

Page 666: ...x 8 mm screw Tighten the 5 x 8 mm screws to the specified torque TORQUE 2 5 N m 0 25 kgf m 1 8 lbf ft 4 Check the inner wall of the yoke for foreign material and install the rear bracket armature assembly Install the rear bracket armature assembly by aligning the grommet with the cutout in the yoke 5 Install the plate and gasket on the front bracket 6 Install the yoke rear bracket assembly Install...

Page 667: ...er assembling the starter motor apply sufficient amount of the water resisting sealant Sumitomo 3M Padding Sealer 8533 or equivalent to the following mating sections 3 SPRING 4 PLUNGER 4 PLUNGER 2 STARTER MAGNETIC SWITCH 2 WIRE GROMMET AND REAR BRACKET 3 SWITCH ASSEMBLY FRONT BRACKET MATING SECTION 4 SWITCH MOUNTING SCREW 5 O RING INSTALLATION PART 1 8 mm WASHER NUT 1 MAGNETIC SWITCH CASE CAULKING...

Page 668: ...m 1 1 kgf m 8 lbf ft 5 Install the 8 mm washer and the alternator fuse cable on the starter magnetic switch and tighten the 8 mm washer nut to the specified torque TORQUE 11 N m 1 1 kgf m 8 lbf ft 6 Connect the main relay White terminal to the starter magnetic switch 7 Install the terminal cover securely 2 STARTER MOTOR 5 STARTER CABLE 6 MAIN RELAY TERMINAL W 8 STARTER MAGNETIC SWITCH 7 10 x 90 2 ...

Page 669: ... and disconnect the two 8 mm washer nuts alternator fuse cable 8 mm washer and the positive starter cable from the magnetic switch B terminal 5 Remove the 8 x 18 mm flange bolt from the crankcase then disconnect the negative starter cable 6 Remove the harness band clip that secures the starter cable from the cable bracket B Remove the wire harness clip 1 STARTER CABLE 1P CONNECTOR W WIRE 2 CONNECT...

Page 670: ...3 STARTER CABLE 1P CONNECTOR W WIRE 2 ALTERNATOR FUSE CABLE 13 8 mm WASHER 12 STARTER CABLE 6 STARTER CABLE 8 CABLE BRACKET B 7 HARNESS BAND CLIP 11 WIRE HARNESS CLIP 2 4 CABLE BRACKET A 8 x 18 26 N m 2 7 kgf m 20 lbf ft 1 8 mm WASHER NUT 2 11 N m 1 1 kgf m 8 lbf ft 7 Release the starter cable from the cable bracket A ...

Page 671: ... 2 7 kgf m 20 lbf ft 3 Install the harness band clip that clamps the starter cable on the cable bracket B 4 Clamp the alternator fuse cable and the starter cable with the wire harness clamp Check that the cables are not interfering with the shift arm NOTICE 1 CABLE BRACKET A 2 STARTER CABLE 2 STARTER CABLE 8 x 18 3 WIRE HARNESS CLIP 4 HARNESS BAND CLIP 1 CABLE BRACKET B 1 CABLE BRACKET A 2 STARTER...

Page 672: ...RQUE 11 N m 1 1 kgf m 8 lbf ft After tightening set the 8 mm washer on the magnetic switch B terminal 6 Install the alternator fuse cable on the magnetic switch B terminal at right angles to the vertical center line of the magnetic switch as shown Tighten the 8 mm washer nut to the specified torque TORQUE 11 N m 1 1 kgf m 8 lbf ft After tightening set the terminal cover on the magnetic switch B te...

Page 673: ...llowing parts Engine cover P 4 2 R engine under cover P 4 9 On installation position each connector and harness in the proper position P 2 48 1 ELECTRIC PART COVER 5 ECM ELECTRONIC CONTROL MODULE 4 ECM CONNECTOR B 34P CONNECTOR 3 ECM CONNECTOR A 26P CONNECTOR 2 ECM CONNECTOR C 6P CONNECTOR 6 x 20 2 ...

Page 674: ...ternator fuse cable from the starter motor On installation position each connector and harness in the proper position P 2 48 through P 2 51 7 PGM FI MAIN RELAY CONNECTOR WIRE 8 HARNESS BAND CLIP 4 6 x 10 9 CONNECTOR BRACKET B 3 RELAY SUSPENSION 6 ALTERNATOR FUSE CABLE 2 UNIT SUSPENSION 2 6 x 16 2 4 LAF RELAY INSPECTION P 18 25 5 POWER TILT SWITCH INSPECTION P 4 12 1 PGM FI MAIN RELAY INSPECTION P ...

Page 675: ...48 through P 2 51 2 6 mm WASHER NUT 2 6 x 25 2 13 90A FUSE 1 ALTERNATOR FUSE BOX B TERMINAL INSTALLATION P 2 48 11 ALTERNATOR FUSE BOX 3 FUSE BOX COLLAR 2 14 RELAY GROMMET 2 10 6 mm WASHER 2 12 5 x 12 mm SCREW WASHER 2 9 6 x 16 mm BOLT WASHER 2 6 3 x 7 mm SCREW WASHER 2 8 ALTERNATOR FUSE COVER 7 90A SPARE FUSE 5 To ALTERNATOR B TERMINAL 4 To STARTER MOTOR B TERMINAL INSPECTION P 18 25 ASSEMBLY P 1...

Page 676: ...6 mm WASHER 4 6 x 25 4 10 FUSE BOX BRACKET 9 CONNECTOR HOLDER CLIP B 8 FUSE BOX COVER 4 HARNESS CLIP 3 5 HARNESS BAND CLIP 3 3 CONNECTOR BRACKET C 6 BLADE FUSE 6 x 10 5 N m 0 5 kgf m 3 6 lbf ft 7 FUSE BOX INSPECTION P 18 26 REMOVAL P 18 23 ...

Page 677: ... and unlock 2 With the lock unlocked pull the fuse box toward you and remove the fuse box from the fuse box bracket ALTERNATOR FUSE BOX ASSEMBLY Connect the alternator fuse cable White wire to the alternator fuse box from the reverse side Connect so that the marks face the directions shown 1 ALTERNATOR FUSE BOX 2 MARKS ...

Page 678: ...e the continuity between the White Black and the Blue Red terminals of the 2P connector 3 Connect the battery positive terminal to the Black White terminal of the PGM FI main relay 6P connector and the battery negative terminal to the Black Blue terminal There must be continuity between the terminal and the White Yellow terminal of the 4P connector 4 Connect the battery positive terminal to the Wh...

Page 679: ...use box fuse 1 Check the 90A fuse for continuity If there is no continuity replace the 90A fuse with the spare fuse If there is continuity install the 90A fuse on the alternator fuse box and check for continuity between the cable terminals 2 When installing the spare fuse on the reverse side of the cover install so that the stamp of 90A is at your side NOTICE 1 ALTERNATOR FUSE BOX 3 RED TAPE 2 To ...

Page 680: ...ECTOR 3P 5 B CONNECTOR 4P 4 C CONNECTOR 4P 7 CONNECTORS VIEWED FROM THE FRONT SIDE Fuse No Check point 1 Between the terminal and the No 3 terminal of the C connector 2 Between the terminal and the No 2 terminal of the C connector 3 Between the terminal and the No 1 terminal of the C connector 4 Between the A connector No 3 terminal and the B connector No 4 terminal 5 Between the A connector No 2 ...

Page 681: ...per position P 2 53 through P 2 56 6 POWER TILT RELAY 3P CONNECTOR 7 TRIM ANGLE SENSOR 2P CONNECTOR 8 POWER TILT MOTOR 2P CONNECTOR 9 POWER TILT RELAY 1P CONNECTOR 1 MAIN WIRE HARNESS 2 HARNESS BAND CLIP 3 3 TP SENSOR 3P CONNECTOR 11 ALTERNATOR FUSE CABLE 12 NEUTRAL SWITCH 2P CONNECTOR 10 FUEL TUBE A INSPECTION Check for deterioration and cracks Replace if necessary 4 HARNESS CLIP INSTALLATION Cla...

Page 682: ... HARNESS CLIP 10 RELAY GROMMET 2 9 POWER TILT RELAY 2 WIRE HARNESS CLIP INSTALLATION Clamp the power tilt relay ground cable 1 FRAME GROUND INSTALLATION P 18 29 12 POWER TILT RELAY GROUND CABLE INSTALLATION P 18 29 INSPECTION P 18 29 5 WIRE HARNESS CLIP INSTALLATION Clamp the power tilt relay 3P connector wire 2P connector wire and the 1P connector wire ...

Page 683: ...ion as shown 2 Tighten the 6 x 12 mm flange bolt while pushing each frame ground terminal against the projection on the crankcase 1 PROJECTIONS 4 PROJECTION 1 GROUND WIRE Bl Lb Lg W G Bu 2 FRAME GROUND TERMINAL 3 POWER TILT RELAY GROUND TERMINAL 5 FRAME GROUND TERMINAL Green to Black terminals Continuity Blue to Black terminals Continuity Green to White terminals No continuity Blue to White termin...

Page 684: ...tinuity Green to Black terminals Continuity Blue to Black terminals No continuity Green to White terminals No continuity Blue to White terminals Continuity Connecting positive battery terminal to Light blue terminal Use a known good battery 2 Connect the wires as shown and check for continuity between the following terminals Connecting positive battery terminal to Light green terminal NOTICE ...

Page 685: ... cams Therefore the two intake side valves are driven in the low engine speed cam profile Thus improvement of the torque in full throttle low speed range was realized compared to the conventional fixed valve timing method When the engine speed is high engine rpm is higher than approx 4 300 min 1 rpm the VTEC solenoid valve functions according to the signal from the ECM extruding the rocker arm pis...

Page 686: ...re of these outboard motors the dedicated chain lubrication oil jets are provided on the crankshaft sprocket intake exhaust camshaft sprocket and the driven sprocket These oil jets feature the unique rib shape to collect the lubrication oil around the respective sprockets Effects The chain guide is provided regulating 80 or more of the chain line It thereby regulates deflection of the chain and el...

Page 687: ...e thermostat valve open temperature for the cylinder head cooling water and for the cylinder block cooling water are set at different temperature from each other At the cylinder block side the thermostat valve open temperature is set at the optimum temperature 60 C to prevent oil dilution over cooling during cruising at low speeds with extremely low load At the cylinder head side the thermostat va...

Page 688: ...ured so that its inner surface is exposed to the atmosphere and the outer surface to the exhaust gas When a given voltage is applied between the platinum electrodes the current does not change by applying further voltage between the electrodes However the current value changes in accordance with the oxygen density in the exhaust gas that passed through the diffusion resistance layer Utilizing this...

Page 689: ...BF135A BF150A Side Mount Remote Control Type ...

Page 690: ...20 2 Top Mount Remote Control Type Panel Mount Remote Control Type ...

Page 691: ...RGENCY STOP SWITCH 23 DATA LINK CONNECTOR 24 TACHOMETER PULSE CHECK CONNECTOR 25 FUEL CONSUMPTION METER 26 BARO SENSOR 27 VTEC SOLENOID VALVE 28 SILENCER CASE 29 IAT SENSOR 30 TP SENSOR 31 MAP SENSOR 32 EACV 33 IAC VALVE 34 IAB CONTROL VALVE 35 DIAPHRAGM 36 IGNITION COIL 37 FUEL INJECTOR 38 PRESSURE REGULATOR 39 FUEL PUMP HIGH PRESSURE SIDE 40 ECT SENSOR 2 41 ECT SENSOR 4 42 KNOCK SENSOR 43 CKP SE...

Page 692: ...l pump Flywheel 416 429 12 Crankcase Balancer 430 441 13 Cylinder block Crankshaft Pistons 442 467 14 Propeller Gear case Extension case Oil case 468 563 15 Mounting case Stern bracket Swivel case Power trim Tilt assembly 564 621 16 Steering rod Remote Control box 622 631 17 Cables Shift link bracket Shift arm Neutral switch 632 654 18 Electrical equipment 655 684 19 Operation 685 688 20 System di...

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Honda Marine BF135A, Manual

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